Scanning electron microscopy, secondary ion-mass spectrometry, and XRD structure analysis were used to study the effects of irradiation of a thin Al/Ni film on an Fe substrate system by a high-power ion beam with an energy density ~50J/cm 2 . The irradiated surface is not uniform and contains no craters. A mixed layer which improves the corrosion resistance and the micro-hardness is formed. The results of the experimental studies have interesting industrial application.