Residual stresses and fatigue crack growth in friction surfacing coated Ti-6Al-4V sheets

Dovzhenko, Gleb; Hanke, Stefanie; Staron, Peter; Maawad, Emad; Schreyer, A.; Horstmann, Μ.

doi:10.1016/j.jmatprotec.2018.06.029

Cited by 22 publications

(4 citation statements)

References 19 publications

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“…In the friction surfacing process, when the material moves from advancing to retreating side, it is stopped by the material present in the retreating side [22]. A similar trend of residual stress distribution has also been reported by other researchers [23]. As can be seen in table 3, increasing the traverse speed of rod at constant feeding and rotational speed decreases the extent of tensile residual stress region.…”

Section: Resultssupporting

confidence: 83%

An experimental and theoretical investigation of thermo-mechanical issues in friction surfacing of Al-Mg aluminium alloys: material flow and residual stress

Bararpour¹,

Aval²,

Jamaati³

2020

Modelling Simul. Mater. Sci. Eng.

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Material flow and residual stress distribution during friction surfacing of aluminum alloy AA5083 on aluminum alloy AA5052 substrate have been evaluated employing a three-dimensional model and the finite element software, ABAQUS, as well as experimental investigation. Based on the results, the nature of residual stress in the coating was tensile while getting compressive by straying away from the boundary of the coating. An increment in heat input per unit length of coating has caused a decrease in the maximum tensile residual stress albeit increasing the extent of the region with tensile residual stress. On the advancing side, the velocity vector was larger than the retreating side due to the larger velocity difference between rotating rod and substrate. Moreover, the velocity difference between advancing and retreating sides was much lower in sample with minimum heat input compared to a sample with maximum heat input.

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Section: Resultssupporting

confidence: 83%

An experimental and theoretical investigation of thermo-mechanical issues in friction surfacing of Al-Mg aluminium alloys: material flow and residual stress

Bararpour¹,

Aval²,

Jamaati³

2020

Modelling Simul. Mater. Sci. Eng.

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“…The FS approach can also be used to deposit multiple layer o top of each other, known as multi-layer friction surfacing (MLFS) or friction surfacing layer deposition (FSLD), leading to a solid-state layer deposition process. For coating applications, i.e., deposition of one single layer, FS was successfully performed for various material combinations like steels [12], aluminum alloys [13], copper [14], titanium alloys [15], Inconel [16], magnesium alloys [17], and, e.g., aluminum and steel [18] or low carbon steel over Inconel [19]. Further very challenging dissimilar material combinations are also achievable, as, e.g., Al/Ti joints enabled by hybrid approaches of friction stir welding (FSW) assisted by FS [20].…”

Section: Introductionmentioning

confidence: 99%

Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing

Rath

Kallien

Roos

et al. 2023

Int J Adv Manuf Technol

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Friction surfacing (FS) is a solid-state layer deposition process for metallic materials at temperatures below their melting point. While the bonding of the deposited layers to the substrate is proven suitable for coating applications, so far the mechanical properties of additively manufactured stacks have not been systematically investigated. In particular, the effect of successive deposited FS layers, i.e., repetitive thermo-mechanical loading, on the interface properties as well as anisotropy and strength of the deposited stack is unknown. For this purpose, the mechanical properties of FS deposited multi-layer stacks from dissimilar aluminum alloys have been investigated, characterizing layer-to-layer as well as layer-to-substrate bonding interfaces via micro-flat tensile testing. Furthermore, directional dependencies in the stack and failure mechanisms are analyzed. The results show a homogeneous, fine-grained microstructure with average grain sizes between 4.2 and 4.6 μ m within the deposited material. The resulting tensile properties with no significant directional dependency present an ultimate tensile strength between 320 and 326 MPa exceeding the strength of the AA5083 H112 consumable base material. No difference was obtained in terms of layer-to-layer or layer-to-substrate interface strength. Furthermore, homogeneous hardness was observed within the deposited structure, which is in the range of AA5083 base material’s hardness of 91 HV. The results indicate that the FS process in conjunction with the material used is suitable for additively generated structures and highlight the potential of this solid-state layer deposition technology.

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“…The enhanced generation and maintenance of the passive film is the reason for improved corrosion resistance 47 . Due to the thermo-mechanical processing, the FS process leads to tensile residual stresses in the deposited layer but induces compressive residual stresses in the remaining sample 48 . However, due to the multi-layer nature of the process, the development and distribution of residual stresses are more complex within the deposited structure.…”

Section: Resultsmentioning

confidence: 99%

Corrosion behavior of multi-layer friction surfaced structure from dissimilar aluminum alloys

Antunes Duda,

Kallien,

da Silva Soares

et al. 2024

Sci Rep

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Friction surfacing (FS) is a solid-state coating technology for metallic materials, where the deposition of a consumable material on a substrate is enabled via friction and plastic deformation. The deposited layer material commonly presents a significantly refined microstructure, where corrosion could be an issue due to this grain refinement within the layer deposited, possibly creating micro galvanic pairs. The present work investigates the corrosion behavior of the FS deposited material as well as stud base material and substrate using cyclic polarization tests and open circuit potential (OCP) monitoring. Comparing the FS deposited material and the respective consumable stud base material (both AA5083), the grain size is correlated with the results from the corrosion tests, where the deposited material shows more equiaxed and refined grains in comparison to the stud base material. The cyclic potentiostatic polarization tests showed that the stud base material is more resistant to pitting nucleation presenting smaller pits and a lower amount of pits compared to deposited material and substrate. As a complement to OCP test, the stud base material is also more stable on a chloride solution compared to the substrate and the deposited material.

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Residual stresses and fatigue crack growth in friction surfacing coated Ti-6Al-4V sheets

Cited by 22 publications

References 19 publications

An experimental and theoretical investigation of thermo-mechanical issues in friction surfacing of Al-Mg aluminium alloys: material flow and residual stress

An experimental and theoretical investigation of thermo-mechanical issues in friction surfacing of Al-Mg aluminium alloys: material flow and residual stress

Anisotropy and mechanical properties of dissimilar Al additive manufactured structures generated by multi-layer friction surfacing

Corrosion behavior of multi-layer friction surfaced structure from dissimilar aluminum alloys

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