Influence of friction surfacing process parameters to deposit AA6351-T6 over AA5052-H32 using conventional milling machine

Galvis, Juan Carlos; Oliveira, Pedro Henrique Fernandes; Hupalo, Márcio Ferreira; Martins, Jairo Aparecido; Carvalho, André Luís Moreira de

doi:10.1016/j.jmatprotec.2017.02.016

Cited by 43 publications

(6 citation statements)

References 18 publications

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“…However, the integrity of the bond at the edges of the deposit is mostly inadequate and the same has to be cleared out. The quality of the surface depends on the consumable rod that is to be deposited and when a high strength surfacing material (consumable rod) is used, the thickness of the deposit is usually on the lower side [8]. A major dominance of this process is that being a solid-phase process, metallurgically incompatible materials can be fused.…”

Section: Fig 1 Friction Surfacing Schematic Diagram [7]mentioning

confidence: 99%

“…The study of friction surfacing on aluminum alloys with aluminium composite mechtrode investigated the various parameters and their influence on the properties of coated layers. The impact of rotational tool speed and traverse speed on coating thickness, width, bonding strength and mechanical properties discussed in friction surfacing of AA5xxx coated on AA6xxx [8] and AA6082 on the AA2024 [10]. The influence of process parameters on coating thickness and width in AA5052 coating on AA5052 [11].…”

Section: Fig 1 Friction Surfacing Schematic Diagram [7]mentioning

confidence: 99%

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Uncertainty Error Analysis on Micro Hardness of Al6061-B4C Surface Composites Produced by Friction Surfacing

Mohanasundaram,

Vijay,

et al. 2019

IJEAT

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Friction surfacing is a confined surface modification process of depositing a layer of a consumable tool (Mechtrode) over the base plate (Substrate). This solid-state surfacing opts for dissimilar material and erosion resistant coatings. It is also utilized for localized repairing of worn-out components. In the present study, the hardness of the coated material is compared with the substrate. In this experiment, the Al-B4C composite consumable rod is prepared with Aluminium 6061 alloy and 3, 6, 9, 12 and 15 weight % of B4C by stir casting and coated over the Aluminium 6061 alloy plate. The 25-run experiment is conducted for the combination of the rotational speed, traverse speed and axial load. The combined effect of process parameters and the increase in weight % of B4C results in the change in hardness. The hardness of the coating is enhanced by 65% than the substrate. The uncertainty analysis revealed that it has a good correlation with the hardness standard value and also it has an error of 5%. The ANOVA analysis concluded that the rotational speed and the weight percentage of the reinforcement improved the microhardness of the coating

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Section: Fig 1 Friction Surfacing Schematic Diagram [7]mentioning

confidence: 99%

Section: Fig 1 Friction Surfacing Schematic Diagram [7]mentioning

confidence: 99%

Uncertainty Error Analysis on Micro Hardness of Al6061-B4C Surface Composites Produced by Friction Surfacing

Mohanasundaram,

Vijay,

et al. 2019

IJEAT

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“…The deposition rate (DR), defined as the amount of deposited material per unit time, was calculated from the product between the rod feed rate (V Z ) and the transversal area of the two layers deposited on the substrate 16 . Figure 7a shows the variation of the deposition rate as a function of the rod feed rate used to produce the corresponding deposits under conditions 1B, 2B and 3B, respectively.…”

Section: Rate and Efficiency Of Depositionmentioning

confidence: 99%

“…During processing, the thermomechanical transformations experienced by the consumable rod lead to a decrease in grain size of the deposited material 16,18,19 . This feature is shown in Figure 9, which shows the transversal micrographs in the center of a deposit in the condition 2B, obtained in specific regions selected on the retreating side (RS), center region (CR) and advancing side (AS).…”

Section: Microstructural Analysismentioning

confidence: 99%

Assessment of Process Parameters by Friction Surfacing on the Double Layer Deposition

et al. 2018

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The friction surfacing process of two deposited layers on two deposition surface conditions, i.e., a smooth interface and a rough interface, was investigated. The control parameter of the deposition process was the rod feed rate with the use of a conventional milling machine. Analyzes of the surface characterization and microstructural characterization along the produced deposits were performed. The interface strength of the substrate/deposit1 (smooth) and deposit1/deposit2 (rough) was evaluated by bending tests and the micro-hardness profile along the transverse section of the substrate/deposit1 and deposit1/deposit2. The bending tests revealed the presence of smalls delaminations with no evidence of fracture at the rough deposit1/deposit2 interface (D1/D2) with less predominance in the deposition condition 3B. This suggests that the combination of the travel speed of 5.5 mm/s and an increase in the consumable rod feed rate of (≥5.5 mm/s) increases the adhesive strength of the two produced interfaces.

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“…Instead of the usual parameters (rotation, forward speed, and axial force), the authors varied rotation, consumable rod feed rate (vertical motion) and substrate translation speed using a statistical approach to investigate the influence of setup conditions on the overall performance of the coatings, which was assessed by applying a simple pushoff test [23]. More recently, it was also shown that Al-alloy coatings could be deposited onto dissimilar Al-alloy substrates using a conventional milling machine adapted for FS purposes [24].…”

Section: Introductionmentioning

confidence: 99%

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.

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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.

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Influence of friction surfacing process parameters to deposit AA6351-T6 over AA5052-H32 using conventional milling machine

Cited by 43 publications

References 18 publications

Uncertainty Error Analysis on Micro Hardness of Al6061-B4C Surface Composites Produced by Friction Surfacing

Uncertainty Error Analysis on Micro Hardness of Al6061-B4C Surface Composites Produced by Friction Surfacing

Assessment of Process Parameters by Friction Surfacing on the Double Layer Deposition

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

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