The surface of AZ91 D magnesium alloy was remelted by plasma beam. The microstructure, composition, hardness, wear and corrosion resistance of the plasma remelted layer（PRL） were characterized. The results show that there is extremely fine and dendrite structure in the PRL at low magnification observation, which is still composed of α-Mg and β-Mg17Al12 phases. But at high magnification observation, the microstructure of the PRL is equiaxial crystalline grains with size of 3-5 μm. And also the content of α-Mg phase decreases while that of β-Mg17Al12 increases and distributes more uniformly in α-Mg matrix compared with the substrate. The hardness of the PRL is much higher than that of the substrate. There are plastic deformation, grains uprooting and tearing evidence with tiny even dimples in the tensile fracture of the PRL, which are different from the substrate. Furthermore, the surface wear and corrosion resistance of AZ91 D are improved significantly after plasma remelting.
