Aluminum is one of most common metals in all advanced and modern scientific and technological applications including electrical, electronic, chemical, engineering, energy and medical fields. The performance of aluminum alloys determines to large extent the quality and economic status of the different processes. Aluminum surface structure determine its performance where nano sized grains and layer can improve aluminum properties and performance. In this work, the improvement of aluminum surface structure and formation of nano structured surface grains by laser surface melting (LSM) using Nd-YAG laser under argon atmosphere was investigated. Different power and scanning speed were applied. The physical and chemical properties of the produced surfaces were examined. SEM, EDX and XRD analyses were performed and were correlated to hardness results. Corrosion resistance of the treated surface was investigated to evaluate their performance in aggressive media and chemical and medical applications. From the obtained data it can be concluded that Nd-YAG laser surface melting of aluminum results in formation of 750 micron nano-structured surface layer. Adjustment of LSM parameters could produce 100 nm grains or less. The obtained results showed also that LSM under argon can eliminate the formation of Al2O3 surface layer which may deteriorates the performance in certain applications. Surface layer rich in AlN is formed upon LSM. It was concluded also that corrosion resistance of the treated aluminum surfaces was improved to large extent by LSM.

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