Method for forming alloy layer upon aluminum alloy substrate by irradiating with a CO2 laser, on substrate surface, alloy powder containing substance for alloying and silicon or bismuth

Claim 1

A method for forming an alloy layer on a surface of an aluminum alloy substrate comprising: disposing a powder for alloying upon the surface of said aluminum alloy substrate, said powder for alloying comprising a mixture of a powder of bismuth and a powder of a substance to be alloyed with said aluminum alloy substrate, the average particle size of said bismuth powder in said powder for alloying being not more than about -42 mesh and the bismuth content of said powder for alloying being at least 21%; and irradiating said powder for alloying as disposed upon said surface of said aluminum alloy substrate with a CO 2 laser so as to melt and fuse said powder for alloying and a surface portion of said aluminum alloy substrate thereby to alloy them together; wherein the composition, particle size and disposition on said surface of said aluminum alloy substrate of said powder for alloying, the composition and dimensions of said aluminum alloy substrate, the power output, output mode, beam pattern and beam scanning speed of said laser, and the atmosphere of melting and fusing of said powder for alloying and the surface portion of said aluminum alloy substrate are such that, when neither silicon nor bismuth are included in said powder for alloying, substantially no alloy layer is formed on the surface portion of said aluminum alloy substrate; and wherein bismuth is incorporated in said powder for alloying so that said alloy layer is formed at an alloying rate which is substantially proportional to the content of bismuth and increases to be substantially 100 percent before the content of bismuth reaches approximately 50 percent.

Claim 2

A method for forming an alloy layer on a surface of an aluminum alloy substrate comprising: disposing a powder for alloying upon the surface of said aluminum alloy substrate, said powder for alloying comprising a mixture of a powder of bismuth and a powder of a substance to be alloyed with said aluminum alloy substrate, the average particle size of said bismuth powder in said powder for alloying being not more than about -42 mesh and the bismuth content of said powder for alloying being at least 21%; and irradiating said powder for alloying as disposed upon said surface of said aluminum alloy substrate with a CO 2 laser so as to melt and fuse said powder for alloying and a surface portion of said aluminum alloy substrate thereby to alloy them together; wherein the composition, particle size and disposition on said surface of said aluminum alloy substrate of said powder for alloying, the composition and dimensions of said aluminum alloy substrate, the power output, output mode, beam pattern and beam scanning speed of said laser, and the atmosphere of melting and fusing of said powder for alloying and the surface portion of said aluminum alloy substrate are such that, when neither silicon nor bismuth are included in said powder for alloying, substantially no alloy layer is formed on the surface portion of said aluminum alloy substrate; and wherein bismuth is incorporated in said powder for alloying so that said alloy layer is formed at an alloying rate which is substantially proportional to the content of bismuth and increases to be substantially 100 percent before the content of bismuth reaches approximately 50 percent.

Claim 3

A method for forming an alloy layer on a surface of an aluminum alloy substrate, comprising the steps of: (a) disposing a powder for alloying upon the surface of said aluminum alloy substrate, said powder for alloying comprising a powder of an alloy of bismuth and a substance to be alloyed with said aluminum alloy substrate, the average particle size of said powder for alloying being not more than about -42 mesh and the bismuth content of said powder for alloying being at least 15%; and (b) irradiating said powder for alloying as disposed upon said surface of said aluminum alloy substrate with a CO 2 laser so as to melt and fuse said powder for alloying and a surface portion of said aluminum alloy substrate thereby forming an alloy layer on the surface of said aluminum alloy substrate.

Claim 4

A method for forming an alloy layer on a surface of an aluminum alloy substrate, comprising the steps of: (a) disposing a powder for alloying upon the surface of said aluminum alloy substrate, said powder for alloying comprising a powder of an alloy of bismuth and a substance to be alloyed with said aluminum alloy substrate, the average particle size of said powder for alloying being not more than about -42 mesh and the bismuth content of said powder for alloying being at least 15%; and (b) irradiating said powder for alloying as disposed upon said surface of said aluminum alloy substrate with a CO 2 laser so as to melt and fuse said powder for alloying and a surface portion of said aluminum alloy substrate thereby forming an alloy layer on the surface of said aluminum alloy substrate.

Claim 5

A method for forming an alloy layer on a surface of an aluminum alloy substrate comprising: disposing a powder for alloying upon the surface of said aluminum alloy substrate, said powder for alloying comprising a powder of an alloy of bismuth and a substance to be alloyed with said aluminum alloy substrate, the average particle size of said powder for alloying being not more than about -42 mesh and the bismuth content of said powder for alloying being at least 15%; and irradiating said powder for alloying as disposed upon said surface of said aluminum alloy substrate with a CO 2 laser so as to melt and fuse said powder for alloying and a surface portion of said aluminum alloy substrate thereby to alloy them together; wherein the composition, particle size and disposition on said surface of said aluminum alloy substrate of said powder for alloying, the composition and dimensions of said aluminum alloy substrate, the power output, output mode, beam pattern and beam scanning speed of said laser, and the atmosphere of melting and fusing of said powder for alloying and the surface portion of said aluminum alloy substrate are such that, when neither silicon nor bismuth are included in said powder for alloying, substantially no alloy layer is formed on the surface portion of said aluminum alloy substrate; and wherein bismuth is incorporated in said powder for alloying so that said alloy layer is formed at an alloying rate which is substantially proportional to the content of bismuth and increases to be substantially 100 percent before the content of bismuth reaches approximately 50 percent.

Claim 6

A method for forming an alloy layer on a surface of an aluminum alloy substrate comprising: disposing a powder for alloying upon the surface of said aluminum alloy substrate, said powder for alloying comprising a powder of an alloy of bismuth and a substance to be alloyed with said aluminum alloy substrate, the average particle size of said powder for alloying being not more than about -42 mesh and the bismuth content of said powder for alloying being at least 15%; and irradiating said powder for alloying as disposed upon said surface of said aluminum alloy substrate with a CO 2 laser so as to melt and fuse said powder for alloying and a surface portion of said aluminum alloy substrate thereby to alloy them together; wherein the composition, particle size and disposition on said surface of said aluminum alloy substrate of said powder for alloying, the composition and dimensions of said aluminum alloy substrate, the power output, output mode, beam pattern and beam scanning speed of said laser, and the atmosphere of melting and fusing of said powder for alloying and the surface portion of said aluminum alloy substrate are such that, when neither silicon nor bismuth are included in said powder for alloying, substantially no alloy layer is formed on the surface portion of said aluminum alloy substrate; and wherein bismuth is incorporated in said powder for alloying so that said alloy layer is formed at an alloying rate which is substantially proportional to the content of bismuth and increases to be substantially 100 percent before the content of bismuth reaches approximately 50 percent.

Claim 7

A method for forming an alloy layer on a surface of an aluminum alloy substrate, comprising the steps of: (a) disposing a powder for alloying upon the surface of said aluminum alloy substrate, said powder for alloying comprising a mixture of a powder of bismuth and a powder of a substance to be alloyed with said aluminum alloy substrate, the average particle size of said bismuth powder in said powder for alloying being not more than about -42 mesh and the bismuth content of said powder for alloying being at least 21%; and (b) irradiating said powder for alloying as disposed upon said surface of said aluminum alloy substrate with a CO 2 laser so as to melt and fuse said powder for alloying and a surface portion of said aluminum alloy substrate thereby forming an alloy layer on the surface of said aluminum alloy substrate.

Claim 8

A method for forming an alloy layer on a surface of an aluminum alloy substrate, comprising the steps of: (a) disposing a powder for alloying upon the surface of said aluminum alloy substrate, said powder for alloying comprising a mixture of a powder of bismuth and a powder of a substance to be alloyed with said aluminum alloy substrate, the average particle size of said bismuth powder in said powder for alloying being not more than about -42 mesh and the bismuth content of said powder for alloying being at least 21%; and (b) irradiating said powder for alloying as disposed upon said surface of said aluminum alloy substrate with a CO 2 laser so as to melt and fuse said powder for alloying and a surface portion of said aluminum alloy substrate thereby forming an alloy layer on the surface of said aluminum alloy substrate.