Identification of suitable process parameters for friction surfacing of mild steel with AA6063 aluminium alloy

Kumar, Bikash; Reddy, G. Madhusudhan; Mohandas, T.

doi:10.1007/s00170-014-5964-7

Cited by 28 publications

(7 citation statements)

References 11 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In the present study, the experiments were conducted in force controlled mode. AA6063 aluminium alloy coatings were deposited on mild steel for 100 mm in length as per the experimental parameter matrix [12] details given in Table 3. …”

Section: Methodsmentioning

confidence: 99%

Influence of process parameters on physical dimensions of AA6063 aluminium alloy coating on mild steel in friction surfacing

Kumar

Reddy

Mohandas³

2015

Defence Technology

Self Cite

View full text Add to dashboard Cite

An attempt is made in the present study to obtain the relationships among process parameters and physical dimensions of AA6063 aluminium alloy coating on IS2062 mild steel obtained through friction surfacing and their impact on strength and ductility of the coating. Factorial experimental design technique was used to investigate and select the parameter combination to achieve a coating with adequate strength and ductility. Spindle speed, axial force and table traverse speed were observed to be the most significant factors on physical dimensions. It was observed that the thickness of the coating decreased as the coating width increased. In addition, the width and thickness of the coatings are higher at low and high torques. At intermediate torque values, when the force is high, the width of the coating is high, and its thickness is thin; and when the force is low, the width and thickness are low. The interaction effect between axial force (F ) e table traverse speed (Vx) and spindle speed (N ) e table traverse speed (Vx) produced an increasing effect on coating width and thickness, but other interactions exhibited decreasing influence. It has also been observed that sound coatings could be obtained in a narrow set of parameter range as the substrate-coating materials are metallurgically incompatible and have a propensity to form brittle intermetallics.

show abstract

Section: Methodsmentioning

confidence: 99%

Influence of process parameters on physical dimensions of AA6063 aluminium alloy coating on mild steel in friction surfacing

Kumar

Reddy

Mohandas³

2015

Defence Technology

Self Cite

View full text Add to dashboard Cite

show abstract

“…As a consequence, the shearing interface [30] through which metal detaches from the rod and is transferred to the deposit below exceeds the consumable rod diameter. The previous results on FS Al-alloy to steel have shown that coating width can be either smaller or larger than rod diameter, depending on process parameters [16,31], although a survey of the results compiled by Gandra et al [1] of various coating/substrate variations shows that normally coating width is smaller than consumable rod diameter. It appears thus that the substrate/rod material combination should play an important role on the deposit width, possibly in connection with the deformation at the rod tip and the ensuing metal flow.…”

Section: Statistical Analysis and Optimizationmentioning

confidence: 96%

Application of the friction surfacing process in a CNC machining center: a viability assessment for producing Al-alloy coatings on low carbon steel

Silva

Afonso

Silva

et al. 2018

J Braz. Soc. Mech. Sci. Eng.

View full text Add to dashboard Cite

Friction surfacing is a solid-state joining process that can be applied to develop similar or dissimilar combinations/joining partners that exhibit sound mechanical properties while avoiding some of the problems associated with the conventional deposition methods in which fusion is involved. Currently, however, the friction surfacing process is carried out in specialized equipment which do not yet have widespread industrial use. With the objective of exploring new application possibilities, in the present work, the viability of employing the friction surfacing process in a machining center with computerized numerical control was investigated. To this end, the deposition of 6351 Al-alloy coatings on a 1020 carbon steel substrate was pursued. After preliminary tests for determining viable deposition parameters, the influence of process variables (rod diameter, rotation, and forward speed) on coating geometry and mechanical properties was investigated using design of experiments methodology. Adhesion of the coatings was evaluated by applying a simple push-off test. The surface finish of the substrate plate was found to influence heat generation during the deposition process and impacted coating deposition. The results demonstrated that, although parameters must be carefully tuned, the process can be feasibly applied under the experimental conditions investigated, and a maximum push-off force value of 4250 N could be achieved.

show abstract

“…The deposition geometry is also reported as a function of the process parameters and temperature evolution during friction surfacing [109,110]. From the direction of friction surfacing, 6xxx series alloys as the tool material are more explored than 6xxx series alloys as the substrate material [109][110][111][112][113]. In this review, the use of the 6xxx series as the substrate material is considered.…”

Section: Friction Surfacingmentioning

confidence: 99%

Surface Modification of 6xxx Series Aluminum Alloys

et al. 2022

View full text Add to dashboard Cite

Due to their superior mechanical properties, formability, corrosion resistance, and lightweight nature, 6xxx series aluminum (Al) alloys are considered as a promising structural material. Nevertheless, the successful application of these materials depends on their response to the external environment. Recently, designers considered the surface properties an equally important aspect of the component design. Due to this concern, these alloys are subjected to varieties of surface modification methodologies. Many methodologies are explored to modify the 6xxx series Al alloys surfaces effectively. These methods are anodizing, plasma electrolytic oxidation (PEO), cladding, friction stir processing, friction surfacing, melting, alloying, and resolidification using high energy beams, etc. This review work discusses some of these methods, recent research activities on them, important process variables, and their role on the final properties of the surfaces.

show abstract

Identification of suitable process parameters for friction surfacing of mild steel with AA6063 aluminium alloy

Cited by 28 publications

References 11 publications

Influence of process parameters on physical dimensions of AA6063 aluminium alloy coating on mild steel in friction surfacing

Influence of process parameters on physical dimensions of AA6063 aluminium alloy coating on mild steel in friction surfacing

Application of the friction surfacing process in a CNC machining center: a viability assessment for producing Al-alloy coatings on low carbon steel

Surface Modification of 6xxx Series Aluminum Alloys

Contact Info

Product

Resources

About