Laser processed Si coatings with thickness in the range 100–150 μm were produced on AISI type 316L stainless steel substrate using a continuous wave CO2 laser. The experiments were done at a laser power between 1·5 kW and 1 kW, process speeds in the range 33·6–8·3 mm s−1, with a beam diameter of 1·6 mm. The microstructure of the laser processed coating consists of columnar dendrites and fine cellular structures. High temperature phases such as δ-ferrite and γ-austenite were found on the resolidified microstructure. The microanalysis technique demonstrated that the laser clad zone possessed a high concentration of Si. The crack free laser clad zone exhibited high hardness in the range 850–900 HV.
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