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

Abstract

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.

Effect of Epoxy/Al2O3/CeO2 Coating on Corrosion Rate and Mechanical Properties of Mild Steel

“…For sample A, B, and C, there is some reduction in the impact strength with a difference of 0.01J/cm 2 but this value is very small and relatively does not show a major effect due to coating layer. Moreover, there is one report from the previous study, it just shows that the result for impact test in Joule for coating material of polyethylene and polypropylene is around 9.8J, where both values does not show much difference [10][11].…”

Evaluation of Bond Strength on Deposition of Aluminium 6063 Alloy over EN24 Medium Carbon Steel by Friction Surfacing Using Different Mechtrode Diameter

“…In their experimental work, Stegmueller et al [13] made a study of the inductive heating effect between stainless steel and aluminium substrate and found an increase in the rotational speed causing a decrease in the coating mass and thickness but an increase in flash masses of the consumable rod. Vijaya Kumar et al [14] attempted at a relationship among process parameters and physical dimensions of the coating between aluminium and mild steel and observed that parameters like a spindle speed, an axial force, and a traverse speed were the most significant factors for preparing the physical dimensions of the coating. Fitseva et al [15] investigated the influence of the rotational speed on the process parameters and material flow on friction surfaced titanium alloys and found that metallurgical processes which influenced the microstructure and a material flow played an important role during FS.…”

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

“…In the case of Alalloy coating on carbon steel, the focus has mainly been directed towards understanding process mechanics, as well as testing the feasibility of FS materials with high discrepancies in physical properties [16][17][18][19]. Udahya Bat et al also manufactured Al-alloy coatings on carbon steel with the objective of producing an intermetallic iron aluminide layer upon subsequent annealing [20], while Kumar et al investigated the relation between process parameters and coating characteristics in Al-alloy deposits produced over mild steel substrates and observed that sound coatings could be obtained [21].…”