An Effect of Process Parameter on Physical Appearance of Deposited Friction Surfaced Layer: A Feasibility Approach

Friction surfacing (FS) is a practice of producing solid-state coating with the higher metallic strength and forged micro-structure. In friction surfacing produces metallic coating with minimum dilution. Deposition of aluminium alloy (AA) on a mild-steel plate has a vital application in surface engineering field, perhaps in the general fusion-based welding processes it might be not possible due to they both are chemically immiscible to each other and form iron aluminide. Friction surfacing of aluminium on mild-steel substrate in solid-state condition is the attractive and workable option. Rotating consumable rod is rubbed on the substrate, while temperature, pressure and axial load are playing a crucial role to form visco-plastic boundary layer at the consumable rod tip. AA 6351 T6 as a consumable rod with 22 mm diameter and SA 516 Gr 70 6 mm plate is used as a steel substrate. By using different parameters, rotational speed, travers speed, tilt angle and with rate of feeding a set of trials are performed. Effect of friction surfacing parameters on bond width, bond length and consumable rod ring shape investigated experimentally. Final set of parameters is obtained with effective bonding.