Friction surfacing (FS) is a solid state technology with increasing applications in the context of localized surface engineering. FS has been investigated mainly for producing fine grained coatings, which exhibit superior wear and corrosion properties. Since no bulk melting takes place, this process allows the dissimilar joining of materials that would be otherwise incompatible or difficult to deposit by fusion based methods. Several studies also emphasize its energy efficiency and low environmental impact as key advantages when compared with other alternative technologies. Main applications include the repair of worn or damaged surfaces through building up or crack sealing. It has also been applied to enhance surface properties at specific areas in the manufacturing of parts and tools. A wide range of materials combinations has been deposited by FS, mainly alloy and stainless steels. Aluminium, magnesium and titanium alloys have also been investigated, including the production of metal matrix composites. Starting with a brief introduction, this review presents a detailed description of the thermo-mechanical and microstructural transformations, as well as, process modelling approaches. The material combinations investigated so far and the effect of process parameters are also addressed. An overview of the main technologic and equipment 6.2. Pre-heating or cooling concepts .

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Friction surfacing is a solid-state surface engineering technology. Previous studies have shown that underwater friction surfacing has some advantages in efficiency and homogeneity of the deposited material. To use these advantages a water spray cooling system was implemented to achieve a more flexible process. This concept has been investigated by depositing Al alloy AA6082 T6 on AA2024 T351 substrate. The efficiency of the process was increased from 19% to 31% without influencing the properties of the deposited material. Temperature measurements revealed that the intensity and chosen location of cooling also affect the process characteristics and allow modifying the coating geometry.

Friction surfacing (FS) is an advanced solid state process in surface modification with increasing applications in reclaiming worn parts, hardfacing and corrosion protection. The advantages of the process are that materials are deposited in the solid state and the resultant forged microstructure which leads to enhanced mechanical properties. As no melting takes place, the process allows joining of dissimilar materials while avoiding several fusion related problems. The present study addresses the deposition of AA5083-H112 coatings over AA2024-T3 substrates focusing on the influence of the main process parameters such as axial force, rotational speed and deposition speed, in the mechanical properties of the deposits. A performance and geometric analysis of the depositions are also presented. Sound aluminum coatings were produced; plastic deformation and heat generation promotes a dynamic recrystallization of the anisotropic consumable rod, resulting in a fine and homogeneous deposit. The coating presented an increase in ultimate tensile strength and failure deformation of 9% and 6%, respectively. Deposition efficiency between 25 and 50% were obtained, with a maximum of 48% average efficiency observed with 800 RPM, 12 kN and 16 mm/s.