This study investigated the ability of the continuous wave diode laser surface hardening of AISI 410 martensitic stainless steel with a maximum power of 1600 W. Variable process parameters scanning speed (4–7 mm/s), laser power (1200–1600 W) and stand-off distance (65–75 mm) were considered in this study. Microhardness, the geometry of hardened layer (depth and width), microhardness deviation from the base metal microhardness (MHD), microstructure analysis of the laser-hardened zone through optical microscopy and field emission scanning electron microscopy and percentage of the ferrite phase in AISI 410 microstructure by using Clemex software were considered as process output responses. Results confirmed that by increasing the laser power and reducing the scanning speed, the surface hardness and the depth of hardness increase. It is also revealed the width of the hardened area increases by enhancing stand-off distance and reducing the laser power. Maximum hardness of 630 HV0.3 with 2.2 mm depth is obtained. Also, the furnace hardening heat treatment is compared with the laser hardening process. Microstructure, microhardness, and impact tests of the two processes are compared. Results showed that the hardness of the diode laser is 1.4 times the hardness of the furnace hardening heat treatment.
