Laser surface alloyed coatings on Al-12%Si have been eroded in distill
ed water at 20 degrees C using a 20 kHz ultrasonic facility operating
with a 50 mu m peak-to-peak amplitude. Erosion was measured by weight
loss and the damage examined using microscopical techniques. Eight coa
tings were selected for examination on the basis of high hardness and
structural integrity. These consisted of a series of Fe and Ni alloys
each with additions of either Mn, Cu or Cr. The linear erosion rate of
Al-12%Si was 27.6 mg h(-1). This was decreased in the iron alloy coat
ings to 7.2-3.8 mg h(-1) and in the nickel coatings to 2.47-0.71 mg h(
-1). These rates show the erosion resistance of the coatings are bette
r than some structural ceramics. Improvements in the incubation period
were generally less substantial and the results varied greatly from a
lloy to alloy. The main reason for the large increase in resistance of
the coatings to erosion is the densely packed intermetallic compounds
which act as a fine fibre-reinforced composite which restricts the si
ze of the cracks during erosion. It appears that the matrix strengthen
ing through rapid solidification and increased solid solubility is lim
ited. The weakness of the matrix leads to failure by plastic flow and
ductile fracture.