Abstract
Titanium and its alloys, characterized by light weight, excellent corrosion resistance, high strength, low elastic modulus, superior biocompatibility, and outstanding osseointegration, have become one of the mostly widely used metallic materials in aerospace and biomedical fields. However, their relatively low plasticity, hardness, and wear resistance constrain further development and applications. Laser surface treatment (LST) technology, which enhances surface properties without altering the bulk material, has emerged as a beneficial approach to modify the surface of titanium alloys. The research advancements and current applications of LST in surface modification of titanium and its alloys were reviewed. The mechanisms, process parameters, surface characteristics, and microstructures of various LST methods were analyzed, including laser transformation hardening (LTH), laser surface remelting (LSR), laser shock peening (LSP), laser surface alloying (LSA), laser cladding (LC), and composite LST techniques. The applications of LST in aerospace and medical domains were also clarified, as well as existing limitations, future research directions, and insights into the developmental trends of LST for titanium and its alloy materials. The objective is to advance LST innovation and to pave new avenues for the application of titanium alloys in various sectors.
Due to its high specific strength, excellent fatigue resistance, and corrosion resistance, Ti alloy has extensive application in high-end sectors such as biomedicine, aerospace, marine engineering, petroleum drilling, and the automotive industry. However, within these domains, particular emphasis is placed on the surface properties of Ti alloys. In aerospace engineering applications, for instance, the inherent low hardness and poor wear resistance of Ti allo
Laser surface treatment (LST) has garnered significant attention due to its potential in enhancing material surface performanc
LST works by focusing a high-intensity laser beam onto the Ti alloy surface. The energy from the laser heats the surface to a specific temperature, which can cause localized phase changes or melting. After the laser beam is removed, the material rapidly cools down, resulting in modified surface properties. This controlled heating and cooling process can lead to a variety of beneficial effects, including heightened hardness, enhanced wear and corrosion resistance, surface alloying, modified residual stress, improved adhesion, and selective surface alteration.
LST offers advantages like the flexibility to process materials with diverse shapes, strong material adhesion, and a compact heat-affected zon
As shown in

Fig.1 Classification of LST
LH is a LST technique that enhances surface performance by irradiating material surfaces with laser beams at various parameters.
LTH uses a high-energy laser (1

Fig.2 Cross-section microstructure of LTH zone (a), higher magni-fication image of dashed rectangle box area in Fig.2a (b), and SEM image of dashed rectangle box area in Fig.2b (c
The LSR is another LH technique, by which the material surface is partially melted by a high-energy laser beam (1

Fig.3 Micro-topographies of Ti-Zr alloy based on LSR: (a) substrate area and (b) remelting are
In LS
LSA uses a high-energy laser to fuse pre-sprayed ultrafine metal or ceramic materials onto Ti alloy surfaces. LSA rapidly homogenizes solute elements through liquid convection, enabling broader alloy composition choices beyond traditional elements.
LC and LSA processes exhibit similarities, but LC employs lower laser energy than LSA. In LC, the cladding material fully melts while substrate melting is limited (typically ≤10% dilution), minimally affecting cladding compositio
LH adjusts parameters to create a robust surface layer, enhancing performance without altering core properties.
Nanosecond, picosecond, and femtosecond lasers yield distinct surface performance improvements. Femtosecond/picosecond treatment enhances wear resistance, while nano-second treatment yields extended metal-oxide foam surface with wear resistance, showing α-Ti to β-Ti transformation and fragmentatio
LTH process parameters, including laser power, scanning speed, and spot siz
Likewise, laser power, scanning speed, and spot size are vital parameters of LSR. Another essential factor that must be noticed is the duratio
Laser power, exposure time, and the number of impacts are vital in Ti alloy surface modification via LSP. Surface features intensify with laser power. LSP significantly enhances residual stress, hardness, and fatigue life, especially post multiple treatments. Nanosecond laser shock improves fatigue life by 47% (1 impact) and 85% (3 impacts

Fig.4 TEM images and diffraction patterns of TC6 Ti alloy after different LSP impacts: (a) without impact, (b) 1 impact, (c) 3 impacts, (d) 5 impacts, and (e) 10 impact
LSA induces refined composition, fine microstructure, high hardness, and excellent wear resistanc
In laser gas-phase alloying, Zeng et a

Fig.5 SEM images of nitrided T-20Zr-6.5Al-4V samples at different laser powers: (a) 120 W, (b) 180 W, and (c) 240 W; EDS point analysis results of Spot 1 (d) and Spot 2 (e) marked in Fig.5
In laser solid-state alloying, Fogagnolo et a
Similar to LSA's laser parameters, LC is closely tied to laser power, scanning speed, spot size, laser dwell time, et

Fig.6 Microhardness profiles of samples under different laser interaction conditions (dwell time, scanning speed, spot size: 0.3 s, 7.45 mm/s, 2.2361 mm; 0.5 s, 5.766 mm/s, 2.8867 mm; 0.7 s, 4.883 mm/s, 3.4156 mm; 0.9 s, 4.3 mm/s, 3.8729 mm; 1.1 s, 3.9 mm/s, 4.2817 mm, respectively

Fig.7 Wear rate distributio

Fig.8 Cross-sectional microstructures of WC-Co composite coating
The surface performance enhancement achieved through standalone LST techniques may fall short of desired outcomes. Hence, researchers proposed laser hybrid processes to further augment surface properties. The study of Kashyap et a
Combining LSP with shot peening (SP) significantly enhances Ti alloy fatigue performance. This hybrid treatment leads to at least 126.4-fold increase in fatigue life for TB

Fig.9 Morphologies and EDS analysis results of titanium plate after LTH+LNC (a) and LTH (b) treatments; cross-sectional morphological features: after LTH+LNC treatment (c), after LTH treatment (d), and original titanium plate (e
The process parameters of LST and the performance index after surface treatment are stated, and LTH, LSR, and LSP are promising methods to achieve deeper hardening layers, especially for complex components with stringent surface quality and stability requirements. In contrast, LSA and LC create distinctive alloy or cladding layers, diverging from the initial composition. The performance of LC and LS

Fig.10 Processing and performance of LST
However, optimizing laser parameters for attaining the op-timal surface performance remains challenging. The influence of processing parameters is still uncertained, often leading to a trial-and-error approach in parameter determination.
Simultaneously, considering the escalating performance demands in fields such as aerospace and healthcare, relying solely on a single LST technique might be insufficient. The emergence of laser hybrid processes as a solution to enhance surface performance necessitates further exploration of LST process selection, diverse process interaction mechanisms, and applicability on Ti alloys.
LST primarily aims to functionalize material surfaces. Extensively, Ti and its alloys serve as substrates.
Substrate | Processing | Research results | Ref. |
---|---|---|---|
Pure Ti | LTH | Phase transformation zone is composed of fine plate structures induced by β→α martensitic transformation, and the hardness increases by 130%. |
[ |
Ti plate (Fe: 0.3; C: 0.08; N: 0.03; H: 0.015; O: 0.25) | LTH+LNC | Surface hardness and wear resistance are improved, and mitigating cracking is related to single LTH, owing to grain refinement in the nitrided layer (60 μm, TiN and α-Ti phases). |
[ |
TC11 | LTH | The fretting fatigue life is increased by 110.78% at low stress level and 17.56% at high stress level. |
[ |
Pure Ti | LTH | Grain boundary migration behavior of pure titanium under laser-induced non-isothermal conditions is the same as that under isothermal conditions, but the prior β grain growth kinetics is largely accelerated due to the high heat input from the laser beam. |
[ |
Ti-6Al-4V | LSR | Melted zone is composed of fine martensitic plates with dense {101} nanotwins inside them. Heat affected zone is comprised of β particles, martensitic plates, and untransformed bulk α grains. Hardness increases in melted zone due to grain refinement, nanotwins, and solid solution. |
[ |
Ti-Zr-Hf-Ta-Nb | LSR | The average grain size in gradient nanostructured layer is refined from 200 µm of matrix to only 8 nm of the top surface. The gradient nanostructure shows significantly enhanced wear resistance, reducing the wear rate with an order of magnitude. |
[ |
Ti-47Al-2Cr-2V | LSR | Dendrite arm spacing of TiAl alloys mainly depends on the temperature gradient. |
[ |
Ti-6Al-4V | LSR | The acicular martensite α′ phase occupies the microstructure of the sample before and after laser remelting. |
[ |
TC17 | LSP | As the laser energy increases, the surface roughness decreases and the residual stress increases. |
[ |
Ti-6Al-4V | LSP+SP | Gradient microstructure with dislocations and novel CRS distribution can be induced. Fatigue crack initiation can be hindered by the high-density dislocation layer. Fatigue crack growth rate can be retarded by the dislocation proliferation layer. |
[ |
Ti-6Al-4V | LSP+SP | Dislocations and deformation twins are induced in the subsurface layer and the original coarse grains are refined, especially at 15 μm near-surface location. |
[ |
Ti-6Al-4V | LSP | Enhanced tribological performance results from a synergy among laser-induced periodic surface structures, titanium oxide, high compressive residual stress, and gradient grain size distribution in laser surface treatment. |
[ |
Pure Ti | LSA (N2+O2 in air) | The phase transformation steps during the laser melting and cooling process are found to be α-Ti→β-Ti→α-Ti+β-Ti→α-Ti+TiN+TiNx (+LTO)→liquid+TiN (+LTO)→TiN+TiOxNy (+LTO) → TiO2+TiN. |
[ |
Ti-20Zr-6.5Al-4V | LSA (N2) | Dense TiN dendrites and (α+β)-Ti (remelting zone, RMZ) and nanoscale α laths are doped with part of β phase (heat-affected zone). Increasing laser power raises TiN dendrite content, resulting in higher surface hardness. |
[ |
TA2 | LSA (N2) | The thickness of the alloying layer and the depth of the lath zone increase with the increase in nitriding passes. |
[ |
Ti-6Al-4V | LC (WC+ NiCrBSi powder) | Laser cladding for 0.3 s produces a high-quality layer with uniform WC dispersion in the NiCrSiB matrix, which is nonporous and crack-free, and exhibits high microhardness (13 563.2 MPa) and superior wear resistance due to low dilution (25%). |
[ |
Ti-6Al-4V | LC (Ni, B4C, graphite, Si3N4) | Wear resistance is improved due to high hardness, excellent lubrication and toughness. |
[ |
TC21 | LC (5Ti:4Ni:1SiC) | The composite coatings consist of Ti2Ni, TiNi, Ti5Si3, and TiC phases. Nano-SiC coating has better hardness and wear resistance due to TiC reinforcement and compact microstructure. |
[ |
TA2 | LC (WS2-TiC-Ti powders) | α-Ti, TiS, Ti2SC, (Ti, W)C1-x, and TiC are in-situ synthesized. The microhardness of the coating is improved significantly due to the formation of carbide ceramics Ti2SC, (Ti,W)C1-x, and TiC, and exceptional wear resistance is observed at 500 °C. |
[ |
Ti-6Al-4V | LC (Ni-based alloy+TaC) | TaC addition forms Ta2O5 in the passive film, improving corrosion resistance of titanium coating due to its superior stability. |
[ |
Substrate | Processing | Research results | Ref. |
---|---|---|---|
Ti-6Al-4V | LC (Ti+B4C powders)+heat treatment | Phase composition and microstructure of the heat-treated coatings are virtually identical to those of the untreated coatings; however, the precipitation of acicular TiB enhances mechanical properties of the heat-treated coatings. |
[ |
Ti-6Al-4V |
Laser texturing+ heat treatment | Combination of LST and heat treatment improves rutile phase fraction, surface hardness and adhesion. Anatase to rutile transformation is prominent mechanism in laser-textured heat treated Ti-6Al-4V surface. |
[ |
Ti and Ti alloys find extensive applications across various sectors, including aerospace, medical industry, providing lightweight, durable, and superior performance as various product components. This section will delve into the LST application for modifying Ti alloy surfaces in aerospace and medical treatment fields.
Ti alloys play vital roles in aviatio
For example, in aircraft operations, foreign objects like birds and debris ingested by engines cause foreign object damage (FOD) to fan/compressor blade
Furthermore, research by Nie et a
Wang et a

Fig.11 Average microhardness distributions at cross section of Ti-6Al-4V alloy aerofoil specimen
Application of LC technique in aerospace is also notably significant. Addressing aerospace's imperative for high speci-fic strength, high-temperature resistance, and wear-resistant alloys, Jiang et a
In aerospace and gas turbine environments, temperatures have reached high-temperature alloy limits. Thermal barrier coatings merge metal performance with ceramic high-temperature resistanc
Ti and its alloys, with superior mechanical properties, corrosion resistance, and biocompatibility, find extensive applications in biomedicine, especially as implant materials due to their low elastic modulus and high biocom-patibilit
However, both pure Ti and its alloys encounter post-implantation inflammation. Even alloys with Young's modulus closely matching that of bone lack reactivity, leading to mechanical fixation-related micro-motion and debris-induced inflammatio
Hence, numerous researchers use LST to enhance surface properties of Ti alloys, aiming to extend their lifespan in medical applications. For instance, Atta

Fig.12 SEM images of MC3T3-E1 cells cultured on untreated (a, c, e) and laser-treated (b, d, f) TZNT alloys: (a‒b) 12 h, (c‒d) 24 h, and (e‒f) 72
Ti and its alloy as the advanced materials capable of withstanding extreme conditions are crucial in aerospace, medical, and other sectors. LST's notable role in these fields highlights its significance, showcasing its promising potential across these applications. Typical applications of titanium alloy LST in the aerospace and medical fields are listed in
Application | Alloy | Processing | Performance | Ref. |
---|---|---|---|---|
Resisting FOD in airraft engine fan blades | TC17 | LSP | Fatigue strength increases after FOD compared to the non-LSP condition. |
[ |
TC11 | LSP | Laser shock peening effectively reduces the depth of damage pits. |
[ | |
Ti-6Al-4V | LSP+SP | The damage caused by low energy impact can be effectively resisted. |
[ | |
Surface modifica-tion of aerospace parts with complex structures | TC11 | LTH | The fretting fatigue life is increased. |
[ |
Ti-6Al-4V | LC (Ni-based+TaC) | With increasing the TaC content, the corrosion trend gradually decreases. |
[ | |
Ti-6Al-4V | LC (B) | Microhardness increases, and tensile strength rises. |
[ | |
Aerospace and gas turbine engine oxidation-resistant coatings | Ti-6Al-4V | LC (NiCrAlSi) | The oxide film composed of continuous dense Al2O3 and NiO effectively prevents oxygen atoms from corroding the substrate, significantly enhancing oxidation resistance. |
[ |
Ti-6Al-4V | LC | Relative oxidation resistance values of 6.83 and 1.94 can be achieved at 600 and 800 °C, respectively. |
[ | |
Ti-6Al-4V | LC (Ni-Al-Ti) | Reducing the extent of Ti segregation in the alloy leads to increased coating oxidation resistance. |
[ | |
Ti-6Al-4V | LSA (N2) | The secondary creep rate reduces for all laser nitriding conditions. |
[ |
Application | Material | Processing | Performance | Ref. |
---|---|---|---|---|
Enhancing biocompatibility | Ti-6Al-4V | LC (Ti powder) | The in vitro test in Hank's solution confirmed that leaching is inside the preferred values. |
[ |
Ti-6Al-4V | LC (HA/HT/T gradient cladding layers) | The Ca/P ratio is closer to that of natural bone, indicating superior biocompatibility. |
[ | |
Improving the surface perfor-mance of im-plants | Pure Ti | LSA (N2+Ar) | Electrochemical experiments in SBF confirm the improved corrosion resistance. |
[ |
Ti-20Zr-10Nb-4Ta | Laser treatment creating grooved structures | Improving corrosion resistance and maintaining cell compatibility can both be achieved. |
[ | |
Ti-6Al-4V | LC (HA/TC4) | The surface is uniform, smooth, exhibits good wear resistance, and has excellent biocompatibility. |
[ | |
Pure Ti | LSR | Microhardness, compressive strength, and ultimate tensile strength are enhanced. |
[ | |
Ti-64 | LSA (N2) | Formation of TiN dendrites in the surface layer significantly improves wear resistance. |
[ | |
Nitinol | LC (CaCO3+Ca3(PO4)2) | Surface modulus of elasticity is found in 6‒30 GPa range, similar to that of natural bone. |
[ |
In the field of aerospace, the surface strengthening effect of LST may not be obvious for some parts that are often subjected to friction, because the thickness of the hardened layer, alloy layer, and cladding layer is limited and cannot adapt to rapid and massive wear.
In the field of medical treatment, Ti and its alloys are crucial for enhancing biocompatibility of medical implants, while actual requirements extend beyond good biocompa-tibility alon
Besides, Ti alloys have an expanding role in maritime applications, the petroleum industry, the automotive industry, and chemical equipmen
Although laser surface strengthening technologies like LTH, LSR, and LSP are mature and widely used for Ti alloy, choosing a best laser parameter to maximize surface performance strengthening remains an ongoing challenge. Both single and hybrid LST methods induce alterations in the microstructure of Ti and its alloy surface layers, thereby resulting in changes in macroscopic mechanical properties. The comprehensive impact of single and hybrid LST techniques on Ti alloys is not fully understood at present. Currently, research primarily involves experimental methods to investigate the influence of LST on the mechanical properties of Ti and its alloy material
In contrast to the hardened layers produced by LTH, LSR and LSP, LSA or LC generates new alloying or cladding layers, altering composition. LC and LS

Fig.13 Utilizing electric-magnetic compound fields to restrict pore formation in LC proces

Fig.14 Utilizing LSR compound fields to restrict pore formation in LC proces
Interdependencies between processing parameters and performance parameters are intricate. Understanding interaction mechanisms between LST parameters and Ti alloy properties to reduce trial-and-error costs is a key goal. In the future, researchers should consider the internal relation among geometric attributes after LST, material properties, microcosmic characteristics and mechanical performance.
Furthermore, gradient coatings can further advance the prospects of LC application
interface performance related to microstructures and bonding
strengt
Attention to LST numerical simulation technology is also rising. It is essential to uncover intricate interplay between input parameters and outcomes. Relationships need to be established among laser parameters, materials' properties, and the surface performance after LS
1) LST significantly improves the surfaces of Ti and its alloys, selectively altering surface layers to improve durability, to enhance efficiency, and to reduce maintenance costs. LST can improve surface properties through alloy phase transformation and enhance surface performance by incorporating external substances or altering alloy surface composition to prepare coatings. LST is comprehensively reviewed, aiming to inspire advancements of Ti alloy surface modifications in various applications. LST boasts adaptable geometry, strong adhesion, and minimal heat impact. Its repeatability and control allow tailored modifications while preserving internal properties. Precision is achieved through power, speed, and path adjustments. Hybrid LST techniques have enhanced efficiency, and an increasing number of LST applications are no longer confined to a single specific technology.
2) The LST technique for enhancing the surface properties of titanium alloys has wide applications in the aerospace and medical fields. Research on the application of LST technique in aerospace engine components primarily targets complex parts such as fan/compressor blades and turbine blades, and high-temperature oxidation-resistant coating
3) An inescapable challenge in the research of LST technique for surface modification of Ti and its alloys is related to equipment development and cost, the demand for highly skilled labor, safety concerns, and the selection of optimal processing parameter
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