Composite coatings, made of nano-Al2O3/cobalt-based alloy, produced by a 5-kW CO2 laser on Ni-based superalloy were investigated. The coatings were examined to reveal their microstructure using optical microscope, scanning electron microscope, transmission electron microscope and X-ray diffraction instrument. The results showed that some equilibrium or non-equilibrium phases, such as gamma-Co, Cr23C6, CoAl2O4, Al2O3 and epsilon-Co existed in the coatings. Fine and short dendritic microstructure and columnar to equiaxed transition occurred by adding nano-Al2O3 particle. With the increase of nano-materials (1%, mass fraction), fully equiaxed crystallization appeared. These were contributed to that nano-Al2O3 particles acted as new nucleation site and rapid solidification of the melted pool. The results also showed inhomogeneous dispersion of nano-Al2O3 that resulted in the formation of epsilon-Co phase in the coatings. The sub-micro structure of the clad was stacking fault. The mechanism of formation of equiaxed grains was also analyzed. (C) 2005 Elsevier Ltd. All rights reserved.
