A 2 kW continuous wave CO2 laser with TEM00 mode structure was used to clad different mixtures of Ni-Al premixed powders on the Inconel 617 substrate under different cladding speeds (1-35 mm/s for premixed clad powder mixture of Ni-10%Al and 1.65-11.2 mm/s for premixed clad powder mixture of Ni-30%Al). EDX and XRD analyses were used successfully to knowledge the changes in chemical composition and built up phases in the clad layers respectively. The results showed that remarkable changes in the percentage of aluminum in laser clad layers are obtained compared with its percentage in starting powder. The results also showed that two phases are present in the clad layers regardless of the the starting powder chemical composition. These are Ni3Al intermetallic compound phase and supersaturated solid solution phase.

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