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Influence on hexagonal closed structure and mechanical properties of outer heat treatment cycle and plasma arc transfer Ti54Al23Si8Ni5XNb+Ta coating for Mg alloy by selective laser melting process

  • Lakshmanan Mariappan EMAIL logo and Ramar Mariappan
Published/Copyright: October 13, 2025
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High Temperature Materials and Processes
From the journal High Temperature Materials and Processes Volume 44 Issue 1

Abstract

Selective laser melting was used to manufacture the magnesium Mg–Al–Zn–X–Mn (Mg) alloy samples, while outer heat treatment cycles (HTC) and plasma arc transfer (PAT) Ti54Al23Si8Ni5XNb+Ta coating technique were used to improve the outer surface. On selective laser melting (SLM) samples, the hexagonal closed structure, Mg2Al3, and α′-MgSi structure produced the strong bonding strength. MgOx phase, MgZn structure, and the Al–Mg–Si ternary phase all significantly improved the outer surface layer after heat treatment at 1,200–1,350°C. At PAT coating samples, the Mg–Si phase, Ti–Al–Mg–Mo phase, Ti–Mg structure, and Ti-twin boundaries were observed, while the outer surface was shielded by the AlSi structure, Ti-inter binary phase, and AlMn basket structure. According to the texture image, MgTi1<0001>, MgTi2<1011>, and MgTi3<2110> MgTi4<2121> outer layers were shielded by the magnesium lattice ternary phase. HTC samples had an 8% harder surface than Mg-SLM samples, but PAT coated samples had a 21% harder surface in both the inner and outer layers. The (µ/β) Mg-coarse grain boundaries, β-MgTi phase, and Ti–Si–Mn structure steadily increased. HTC samples had an average tensile strength of 8% elongation, but PAT coating samples showed a high yield strength and ductility ratio of 13%. The surface roughness, corrosion rate, and wear resistance of the Mg-SLM sample were studied as the outer layer HTC and PAT coated samples were gradually enhanced.

Keywords: selective laser melting; Mg alloy; plasma arc transfer; Ti-inter binary phase; tribology behaviors

Nomenclature

C

deposition speed (mm·h−1)

f

focus distance (mm)

I

heat input (J)

J

current density (A·dm−2)

p

load (g)

P

power (W)

S

speed (mm·min−1)

t

thickness (mm)

T

temperature (C)

ϵ

strain rate (mm·min−1)

Δ

regular interval

HV

Vickers hardness number

1 Introduction

Magnesium powder alloy samples were among the lightest and strongest structural materials known, with great bonding strength and low density. These materials are used in several industries, including automotive, aerospace, mobile, chemical, and medical [1–3]. Whereas the Mg-selective laser melting (SLM) technique was very supportive for the cardiovascular stents, bone fixing plate, and bone fixing screw. The selective laser melting process used magnesium powder particle to improve molding precision and maximize material use [4]. The solid particle and additive molding samples made with SLM technique showed a sudden increase in terms of mechanical characteristics, resistance to corrosion, and durability. The high-quality result was produced by utilizing several parameters such as laser energy density, laser power, focus distance, and particle size in the SLM process of ZK60 magnesium materials [5]. In order to enhance the microstructure and chemical composition of the WE43-Mg samples, Esmaily et al. suggested that the SLM was evenly dispersed in the zirconium-rich oxide particles [6]. The samples of titanium alloys, as determined by the SLM method, showed a heterogeneous structure with columnar β and acicular α′ grains; the average elongation was 14% and the tensile strength was 1,081 MPa [7]. Yan et al. unequivocally demonstrated how the W–Cu composite’s mechanical, thermal, and surface characteristics were abruptly increased by a selective laser melting technique [8]. Younsi et al. [9] revealed that while the thickness and micro hardness of the laser powder layer increased steadily, the surface properties and microstructure of the SLM process were gradually improved by the cobalt-based alloy coatings approach. According to Bolelli et al.’s investigation, the SLM surfaces received greater support from the pre-treatment and thermal spray coating procedure, but their mechanical qualities, strong adhesion, and bonding strength unexpectedly increased [10]. Porosity and corrosion rate were decreased during the coating process, while structural qualities and energy absorption capacity were increased [11]. Additionally, titanium, stainless steel, and magnesium alloy powder were produced with greater strength during the SLM process, which was further supported by the thin wall structure and product handling procedure. High adhesion and tensile strength of 20 GPa were improved by the diamond-like carbon coating technique, while wear resistance and delamination structure were avoided by the heat inputs of the coating process [12–15]. The Ti-SLM samples were found in the SiC particles and interlayer interfaces, which enhance the outer surface’s SiC phase and Ti5Si3Cx phase homogeneities [16,17]. Using SLM samples, the Ti6Al4V alloy sample underwent gas nitriding and amorphous carbon nitride treatments. The SLM, annealing, and coating procedure improved the greatest resistance to corrosion, outstanding mechanical strength, and maximum wear resistance [18].

Utilizing selective laser melting, the novel research project was conducted on an Mg-Al–Zn–X–Mn alloy. The Mg-SLM process was performed on 2 mm thick sheets using a constant process parameter. Biomedical equipment, automotive part, and disabled person parts from Mg-SLM samples have been produced. By decreasing the holes, pores, dimples, and voids in the outer surface layer and plasma arc transfer (PAT) Ti54Al23Si8Ni5XNb+Ta coating, the outer heat treatment cycle (HTC) enhanced the microstructure and surface properties. In addition to reducing corrosion and increasing wear resistance, the hardness procedure also protected the outside surface of the Mg-SLM samples by distributing heat inputs gradually [19].

2 Experimental

The commercially available Mg–Al–Zn-X–Mn alloy powder has an average particle size of 20–30 µm and was created by a selective melting process. To protect the surface layer and reinforce the bonding structure, 99.99% pure argon gas was used in the SLM process. The chemical composition of the Mg materials components is given in Table 1. Using SLM techniques, examinations into process parameters were conducted: 1.2 hatch distance (mm), 800 scanning speed V (mm·s−1), and 250 laser power P (W) was utilized. In order to improve the tribological properties and hardness value of the foundational materials, the SLM technique employed a two-layer structure with a 1 mm thickness and a 2 mm total thickness as shown in Figure 1. The cycle of exterior heat treatment was run at temperatures between 1,200 and 1,350°C for 6 h. Pure 9.99% argon gas was used in both the inner and outer surface regions during the fast-cooling procedure [20]. Plasma spray coating was supported by Spraymet Surface Technologies Pvt. Ltd in Bangalore, with the following process parameters maintained: focus arc distance of 30 mm, deposition speed of 30 μm·h−1, and current plasma density of 25–4 A·dm−2.

Table 1

Chemical composition of Mg alloy samples

Al Zn Mn Fe Si Mg
3% 1% 0.0075 0.0025 0.003 Balance
Figure 1 (a) and (b) 1,200–1,350°C HTC and (c) and (d) PAT Ti54Al23Si8Ni5XNb+Ta coating by selective laser melting process.
Figure 1

(a) and (b) 1,200–1,350°C HTC and (c) and (d) PAT Ti54Al23Si8Ni5XNb+Ta coating by selective laser melting process.

2.1 Metallurgical studies of outer HTC and PAT Ti54Al23Si8Ni5XNb+Ta coating

The outer HTC and PAT Ti54Al23Si8Ni5XNb+Ta coating are used in the chemical, aerospace, automotive, marine, food, and biomedical industries. The metallurgical investigations involved Mg-SLM samples with PAT Ti54Al23Si8Ni5XNb+Ta coating and an outer HTC. The dark etchant technique was performed on an Mg-SLM sample at 60% NaCl + 5 g K + 30% H2O + 5% HCl. The Mg-SLM, HCT, and PAT coated samples were subjected to studies on Vickers hardness. The geometrical profile and Vickers hardness values were measured under a standard load of 500 g, with a dwell time of 10 s, and at uniform intervals of 0.50 mm. All Mg-SLM samples with diameters of 10 × 10 × 2 mm3 underwent potential dynamic polarization experiments using the IM8 Zahner potentiostat device. For corrosion resistance, a 3.5% NaCl solution (salt in saltwater) with a 20 min potential open loop circuit was used. Wear tests were conducted on the Mg-SLM sample on the outer surface layer for 15–20 min at a sliding speed of 200 mm·min−1 and a wear load of 30 N. On the other hand, measurements were taken at the Mg-SLM, HCT, and PAT coated for the longitudinal, abrasive, and deep grooves [21].

3 Results and discussion

3.1 α′-MgSi structure of Mg-SLM for outer heat treatment process

A 2 mm thick sheet with a constant thickness of 800 laser power P (W), 250 scanning speed V (mm·s−1), and 1.2 hatch distance (mm) was used in the selective laser melting method to create the additive process. The Mg-SLM technique used a procedure of continuous heat input to create a strong layer and solid structure [7]. While the oxygen reduction process was carried out in the inner surface layer of the Mg-SLM process, the bonding characteristics were steadily increasing the heat inputs of the Mg-SLM process. The essential function of the primary and secondary argon gases was to support the microstructure and bonding strength. The heat inputs in the Mg-SLM process created the MgOx phase, MgZn structure, and Mg/MnZn phase as shown in Figure 2. By avoiding cracks, dimples, and holes in both the inner and outer layers, the heat-treated Mg-SLM samples enhanced their mechanical strength and wear characteristics [16]. The heat treatment method at 1,200°C resulted in the creation of an oxide layer, homogenous µ′-Mg coarse grain boundaries, and Mg twin boundary structure. However, the inner layer of Mg-SLM samples was unaffected, and the outer surface layer and bonding strength were enhanced [19]. The inner layer created the α′-MgSi structure, the Al–Mg–Si ternary phase, and Mg2Al3. The inner and outer layers were mostly influenced by the heat treatment process at 1,350°C. Heat radiation was functioning as a distinct zone, while the node has been designated as a boundary structure as shown in Figure 2. On this nodal border structure, the radiative intensity along incoming discrete directions is defined by

I i = ε I b ( T ) + 1 − ε π q r out

Figure 2 OM image (a)–(c) Mg-SLM for outer heat treatment process sample by Mg-SLM samples.
Figure 2

OM image (a)–(c) Mg-SLM for outer heat treatment process sample by Mg-SLM samples.

Although the interior structure of the Mg, Al, Zn, and Fe elements was abruptly rising, the heat treatment procedure was lowering the internal stress and oxidation layers. Improved Mg/Mn phase and Mg-coarse grain boundary structure have achieved by reflecting the texture image of Mg1<0001>, Mg2<1011>, Mg3<2110>, and Mg4<2121> on heat-treated samples into the outer surface layer as shown in Figure 3. The 1,350°C on heat treatment process was increasing the Mg/Zn boundaries’ structure, SiZn/MnSi phase, β′-MgFe structure, and Al–Mg phase observed in the inner solid structure [1,2]. The Mg-SLM samples’ elongation and re-bonding microstructure were enhanced, while the outer heat inputs had a direct impact on the inner and outer surface regions, as demonstrated by the optical microscope (OM) and scanning electron microscope (SEM) images (3 & 4). The Mg phase, Mg17Al12 phase, and Mg refined grain boundaries were created by the heat input of the HTC process on the OM image 3. Grain size increased by −14 µm, and fraction angle reached 0.18 in order to improve the outer surface’s mechanical strength and hardness value and prevent cracks, holes, and pores. Grain size, boundary structure, and the outer surface region were all impacted by temperatures of 1,200 and 1,350°C, according to finite element simulation methods, although the heat input process was more affected by the outside surface of the edge surface. The finite element analysis (FEA) methods were forming the degrees of freedom, boundary conditions, node elements, and strain ratio, whereas heat inputs were increasing the stress–strain value for the boundary structures to support plasticity, hardening, and elasticity. These variables (heat inputs, stress, strain, and boundary conditions) are all increasing the nodal characteristics. That nodal technique was lowering the prediction problem and increasing the accuracy. The exterior layers’ fractures, holes, and dimples were being lessened by the magnesium secondaries, the Mg/Si basket structure, and the Mg oxide phase as shown in Figure 4. Moreover, heat treatment reduced the outer layer’s CrN and Cr2N by a small amount, but the lattice structure and grain size prevented corrosion and wear. The Mg-SLM method exhibited a strong bonding strength and inner structure. However, the outer surface layer somewhat increased the hardness value and elongation ratio of the Mg-SLM samples following heat treatment. The outer surface’s holes and brittle fracture were being lessened by that technique [19,20].

Figure 3 Texture and angle image α′-MgSi structure of Mg-SLM for outer heat treatment process sample.
Figure 3

Texture and angle image α′-MgSi structure of Mg-SLM for outer heat treatment process sample.

Figure 4 OM image, (a)–(d) SEM image, (e)–(g) FEA, and (h) and (i) grain size of Mg-SLM for outer heat treatment process sample.
Figure 4 OM image, (a)–(d) SEM image, (e)–(g) FEA, and (h) and (i) grain size of Mg-SLM for outer heat treatment process sample.
Figure 4

OM image, (a)–(d) SEM image, (e)–(g) FEA, and (h) and (i) grain size of Mg-SLM for outer heat treatment process sample.

3.2 β-MgTi phase of Mg-SLM with PAT Ti54Al23Si8Ni5XNb+Ta coating process

The inner and outer layers were immediately impacted by the heat treatment technique that altered the Mg basket structure and grain boundary structure in greater amounts in the Mg-SLM samples. In order to improve the outer surface layer’s resistance to wear and corrosion, the thickness of the coating was kept at 18 µm during the PAT coating process [12]. The thickness of the coating improved the elongation point and hardness value while shielding the inner surface layer as shown in Figure 5. The creation of the Mg crystal structure, Mg/ZnSi phase, Mg oxide phase, and Mg secondary structure was aided by the PAT Ti54Al23Si8Ni5XNb+Ta coating on heat inputs. The MgTi/TiZn phase, Mg-lattice structure, and TiAl face structure were detected in the inner layer; following the plasma spray coating procedure, the β-TiMg matrix phase, Mg lattice structure, Ti–Si–Mn structure, and (µ/β) Mg-coarse grain boundaries were abruptly rising as shown in Figure 6. The Ti, Mg, Mn, Si, and Tb elements of the outer surface were being increased by the PAT coating process, which was also progressively decreasing the cracks, holes, and large spaces [11]. The procedure of coating involved forming the α-Mg/eutectic, MgSi phase, Mg2Al3, and strong solid layer. Using a PAT coating method, plastic deformation and internal stress were gradually reduced on both the inner and exterior surface [15].

Figure 5 Texture and electron backscatter diffraction image of β-MgTi phase of Mg-SLM with PAT Ti54Al23Si8Ni5XNb+Ta coating process.
Figure 5 Texture and electron backscatter diffraction image of β-MgTi phase of Mg-SLM with PAT Ti54Al23Si8Ni5XNb+Ta coating process.
Figure 5

Texture and electron backscatter diffraction image of β-MgTi phase of Mg-SLM with PAT Ti54Al23Si8Ni5XNb+Ta coating process.

Figure 6 (a–e) SEM image of β-MgTi phase of Mg-SLM with PAT Ti54Al23Si8Ni5XNb+Ta coating process.
Figure 6

(a–e) SEM image of β-MgTi phase of Mg-SLM with PAT Ti54Al23Si8Ni5XNb+Ta coating process.

The PAT coating procedure used oxygen reduction techniques to progress the Mg-SLM samples’ mechanical strength and surface characteristics. Heat inputs were used in the PAT coating process to directly create the Mg-twin and Mg-βʹ grain boundaries [11]. The Mg lattice ternary phase and (β/µ) Mg grain size protected the texture images of the MgTi1<0001>, MgTi2<1011>, and MgTi3<2110> MgTi4<2121> outer layers as shown in Figure 5. While the inner layer bonding strength was abruptly increasing, the outer layer was being protected by the coating thickness and oxygen reduction technique [6,7]. The direct avoidance of CrN and Cr2N during the oxygen reduction process increased the wear resistance and inner atomic structure. When Al+Ni elements bonded straight to the outer surface layer, Ti elements mixed significantly with the PAT coating process [16]. Plasma spray coating, vapor deposition, and high velocity oxy-Fuel coating processes on heat inputs strengthened the outer and inner surface regions of base materials, whereas alloy and ferrite materials relied heavily on heat inputs. Heat inputs were used to improve the microstructure and mechanical properties of base materials.

3.3 Mechanical properties of Mg-SLM samples

For the X-axis direction, the average hardness value was measured on the outside of the Mg-SLM, HTC, and PAT coated samples. The average hardness value of the Mg-SLM sample was reached at 246 HV, while the bonding strength and β′-Mg grain boundary structure of the samples progressively increased as a result of the heat inputs on Mg-SLM sample. HTC samples reached a temperature of 1,200°C on hardness values at 252 HV, with the outer surface displaying the SiZn/MnSi phase, β′-MgFe structure, and Al–Mg phase. When HTC samples were heated to 1,350°C, a hardness value of 261 was reached; significant inner structures were seen in the Mg/Si basket structure, α-Mg oxide phase, and Mg/ZnSi lattice structure [9]. PAT-coated samples with an HTC of 1,200°C were achieved at 274 HV, which means that when the hardness value increased, the fracture, hole, and significant dimples on the outer and inner surfaces decreased gradually. TiSi/MgZn phase, µ-Mg-twin boundaries, and Mg-grain boundaries structure was observed [10]. PAT coated samples with HTC of 1,350°C on hardness value was slightly raised at 278 HV, indicating that the method was protecting the outer surface and Mg inner boundaries structure as shown in Figure 7. While the layer-by-layer deposition process increased the thickness layer and decreased the gaps, pits, and cracks of the surfaces, the PAT Ti54Al23Si8Ni5XNb+Ta coating method created the strong solid structure, outer bonding strength, and knitting structure [19].

Figure 7 (a and b) SEM image of hardness value of HTC and PAT Ti54Al23Si8Ni5XNb+Ta coating process by Mg-SLM.
Figure 7

(a and b) SEM image of hardness value of HTC and PAT Ti54Al23Si8Ni5XNb+Ta coating process by Mg-SLM.

3.4 Studies of corrosion for HTC and PAT coating of Mg-SLM process

Although investigations using 2 h of 3.5% NaCl salt water were undertaken on all Mg-SLM samples, potential dynamics studies were carried out at the Mg-SLM, HTC, and PAT coated samples to improve the corrosion strength and exterior structure [6–9]. The corrosion rate, corrosion potential, and corrosion current (I corr, E corr), were measured using polarization curves as shown in Figure 8. Pits, large cracks, and groove pits were rapidly lowering the outer layer through the use of PAT coating; nevertheless, HTC and PAT coated samples were gradually reduced by current intensity and probable passive process as shown in Figure 9. Heat inputs on HTC samples resulted in an increase in Mg grain boundaries structure, β′-MgFe structure, Ti–Al–Mg phase, and Mg–Si–Zn phase; nonetheless, the process of heat inputs may have created CrN and Cr2N. Nevertheless, pitting and rust did not radiate outward [10]. While α-Mg lattice ternary phase, TiMg phase, Mg2Al3, and (β/µ) Mg grain size was formed in the inner and outer surface region, the PAT coating process was directly increasing the Ti, Mg, Mn, Si, and Tb elements [1]. The PAT coated surface and the Ti and Ni nanoparticles mixed directly, with the Al, Si, and Zn components predominating in the outer surface region as shown in Figure 8. For the Mg -secondary’s structure, Mg/SiMn phase, and Ti/Mg phase misorientation and grain size testing were clearly seen as in Figure 5. Within the outermost layers, several forms of Mg lattice structure and Ti grain boundaries were discernible [20]. The kernel average misorientation test revealed that the proportion reached partition at 0.99–1.000, and the largest grain boundary structure was 5% higher. The exterior surface of the PAT-coated samples did not exhibit any pits, groove voids, minor pits, holes, or cracks [3].

Figure 8 Potential dynamics studies of β-MgTi phase of Mg-SLM with HCT and PAT Ti54Al23Si8Ni5XNb+Ta coating process.
Figure 8

Potential dynamics studies of β-MgTi phase of Mg-SLM with HCT and PAT Ti54Al23Si8Ni5XNb+Ta coating process.

Figure 9 Corrosion images of HCT and PAT Ti54Al23Si8Ni5XNb+Ta coating process.
Figure 9

Corrosion images of HCT and PAT Ti54Al23Si8Ni5XNb+Ta coating process.

3.5 Wear resistance

The wear resistance of Mg-SLM, HTC, and PAT coated samples was tested at wear sliding speed, wear load, and wear time. On the outer surface, 30 N load and constant time were applied for 15–20 min as shown in Figure 10. The focus of wear abrasive and friction loss experiments was consistently on all Mg-SLM samples. HCT reached 12% wear volume loss on samples heated to 1,200°C, whereas 10% HCT was reached on samples heated to 1,350°C [4]. The outer surface was protected by the Mg-grain boundaries, Mg–Al–Zn structure, and α-Mg lattice ternary phase [20]. Though the amount of wear debris, wear groove, and wear depth of groove was marginally reduced in the PAT coated samples, the wear resistance properties of the PAT samples reached on the outer surface. Wear mechanism of PAT coating increased high hardness and elongation while reducing large-size wear, oxide wear debris, and fracture toughness on coated surfaces. Coated samples had better bonding properties, which reduced adhesive and oxidative wear.

Figure 10 Wear resistance of β-MgTi phase of Mg-SLM with HCT and PAT Ti54Al23Si8Ni5XNb+Ta coating process.
Figure 10

Wear resistance of β-MgTi phase of Mg-SLM with HCT and PAT Ti54Al23Si8Ni5XNb+Ta coating process.

The oxidation layers of the PAT samples were being increased by the Ti–Al–Mg–Mo phase, (µ/β) Mg-coarse grain boundaries, β-MgTi phase, and Ti–Si–Mn formation [21]. Wear debris, wear groove pits, and wear abrasive fractures were suddenly reduced in the TiAl phase and AlSi structure. The heat input in the PAT-coated samplesresulted in the formation of a Ti layer and an Al–Mn structure, while the combined Al+Ti layers reduced wear debris, wear cracks, and delamination, as shown in Figure 11. The abrupt increase in layer thickness and support for the wear resistant capabilities can be attributed to the absence of CrN and Cr2N formation in the outer layer. The PAT coating technique and HTC procedures were used to increase wear resistance and prevent delamination [22,23].

Figure 11 (a–e) SEM image of β-MgTi phase of Mg-SLM with HCT and PAT Ti54Al23Si8Ni5XNb+Ta coating process.
Figure 11

(a–e) SEM image of β-MgTi phase of Mg-SLM with HCT and PAT Ti54Al23Si8Ni5XNb+Ta coating process.

3.6 Surface properties

The average surface roughness and peak were measured by conducting surface morphology testing at the outer surface layer of Mg-SLM coated samples as shown in Figure 12. The µ-Mg grain boundaries and (β/α) secondary lattice structure increased steadily during the HTC process, but the outer layer thickness and bonding strength rapidly increased following the plasma spray Ti54Al23Si8Ni5XNb+Ta coating [8]. PTA-coated samples of HCT at 1,350 and 1,200°C reached 9.118 and 6.274 µm on roughness average (Ra). The HCT of the PTA-coated samples at 1,350 and 1,200°C was obtained with a variation of the roughness profile (Rq) of 10.504 and 7.896 µm [7]. In both PAT coated samples, the average maximum peak height was accomplished between 20.693 and 20.207 µm. The PAT coated samples showed Ti–Al–Mg–Mo, β-MgTi, and Ti–Si–Mn phases on their outer surface, whereas the plasma spray coating method completely eliminated any cracks, holes, or veins as shown in Figure 13. The ternary phase of Al–Mg–Si, the α′-MgSi structure, and Mg2Al3 were found to reduce the oxidation layer, while the SEM of surface roughness reduced wear and corrosion of the outer surface layer [23]. The microstructure and hardness value of the PAT coating process were abruptly increased by average roughness; nevertheless, the internal stress and bonding strength of the Mg-SLM process remained unaffected. The average depth of the roughness profile was determined by the thickness and size of the magnesium grain [4,5]. The outer layer and grain boundaries of the Mg-SLM samples were altered by the heat inputs of the HTC process; additionally, the PAT coating procedures improved the mechanical and surface properties [3].

Figure 12 (a–f) Surface morphology in 2D and 3D views, along with peak values, for PAT Ti54Al23Si8Ni5XNb+Ta coating samples processed at 1,200°C and 1,350°C.
Figure 12

(a–f) Surface morphology in 2D and 3D views, along with peak values, for PAT Ti54Al23Si8Ni5XNb+Ta coating samples processed at 1,200°C and 1,350°C.

Figure 13 (a–c) SEM image on surface properties of β-MgTi phase of Mg-SLM with PAT Ti54Al23Si8Ni5XNb+Ta coating process.
Figure 13

(a–c) SEM image on surface properties of β-MgTi phase of Mg-SLM with PAT Ti54Al23Si8Ni5XNb+Ta coating process.

4 Conclusion

  • The MgZn structure, the MgOx phase, and the Mg/MnZn phase were the heat inputs of the Mg-SLM process. The process parameters for the Mg-SLM samples were 800 P (W) of laser power, 250 V (mm·s−1) of scanning speed, and 1.2 mm of hatch distance.

  • The Mg/Zn boundary structure, SiZn/MnSi phase, β′-MgFe structure, and Al–Mg phase found in the inner solid structure were all growing at 1,350°C of HCT process throughout the heat treatment procedure. On the other hand, an oxide layer, homogenous µ′-Mg coarse grain boundaries, and an Mg twin boundary structure were produced by the heat treatment procedure at 1,200°C of HCT methods.

  • PAT-coated samples with an HTC of 1,350°C on a hardness value that was marginally elevated at 278 HV showed that the technique was shielding the Mg inner boundary structure, the µ-Mg twin boundaries, and the outer surface TiSi/MgZn phase. At 274 HV, PAT-coated samples with an HTC of 1,200°C were obtained.

  • On the outside of the PAT-coated samples, there were no pits, groove voids, tiny pits, holes, or cracks. The elements Ti, Mg, Mn, Si, and Tb were abruptly rising in the PAT samples due to heat inputs, while the HCT and PAT samples were absent from the CrN and Cr2N.

  • The results of the wear test studies showed that the Ti–Al–Mg–Mo phase, β-MgTi phase, (µ/β) Mg-coarse grain boundaries, and Ti–Si–Mn formation were increasing the oxidation layers of the PAT samples. Abrasive cracks, wear debris, and wear groove pits were all abruptly reduced in the AlSi structure and TiAl phase.

Acknowledgments

Not applicable for this study.

  1. Funding information: The authors state no funding involved.

  2. Author contributions: Lakshmanan Mariappan: conception, design, data acquisition, analysis, interpretation, drafting, and critical review; Ramar Mariappan: conception, design, data acquisition, analysis, interpretation, drafting, and critical review.

  3. Conflict of interest: The authors state no conflict of interest.

  4. Data availability statement: No data were generated or used in this study.

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Received: 2024-11-26
Revised: 2025-06-22
Accepted: 2025-06-24
Published Online: 2025-10-13

© 2025 the author(s), published by De Gruyter

This work is licensed under the Creative Commons Attribution 4.0 International License.

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https://doi.org/10.1515/htmp-2025-0089
Keywords for this article
selective laser melting; Mg alloy; plasma arc transfer; Ti-inter binary phase; tribology behaviors
Creative Commons
BY 4.0

Articles in the same Issue

  1. Research Articles
  2. Endpoint carbon content and temperature prediction model in BOF steelmaking based on posterior probability and intra-cluster feature weight online dynamic feature selection
  3. Thermal conductivity of lunar regolith simulant using a thermal microscope
  4. Multiobjective optimization of EDM machining parameters of TIB2 ceramic materials using regression and gray relational analysis
  5. Research on the magnesium reduction process by integrated calcination in vacuum
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  8. Exploring the selective enrichment of vanadium–titanium magnetite concentrate through metallization reduction roasting under the action of additives
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  12. Wide temperature range protection performance of Zr–Ta–B–Si–C ceramic coating under cyclic oxidation and ablation environments
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  14. Aspects of thermal radiation for the second law analysis of magnetized Darcy–Forchheimer movement of Maxwell nanomaterials with Arrhenius energy effects
  15. Use of artificial neural network for optimization of irreversibility analysis in radiative Cross nanofluid flow past an inclined surface with convective boundary conditions
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  17. Significance of micropores for the removal of hydrogen sulfide from oxygen-free gas streams by activated carbon
  18. Experimental and mechanistic studies of gradient pore polymer electrolyte fuel cells
  19. Microstructure and high-temperature oxidation behaviour of AISI 304L stainless steel welds produced by gas tungsten arc welding using the Ar–N2–H2 shielding gas
  20. Mathematical investigation of Fe3O4–Cu/blood hybrid nanofluid flow in stenotic arteries with magnetic and thermal interactions: Duality and stability analysis
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