Tool steel and copper coatings by friction surfacing – A thermography study

Rao, K. Prasad; Sreenu, A. Veera; Rafi, H. Khalid; Libin, M. N.; Balasubramaniam, Krishnan

doi:10.1016/j.jmatprotec.2011.09.023

Cited by 42 publications

(9 citation statements)

References 15 publications

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“…This phenomenon marks the achievement of the necessary starting conditions for FS, i.e., the extension of the plunge period will only result in extra flash formation under constant axial load, with no significant temperature development and no benefits for joining strength. Similar findings were also reported regarding the FS of stainless steels over mild steel by Rafi et al (2011a), copper over copper by Rao et al (2012c) and for aluminium alloys AA6082-T6 over AA2024-T3 by Gandra et al (2013a). Rao et al (2012c) proposed that the localized stress developed due to axial loading at the contact between consumable rod and substrate was equivalent to the flow stress of the plasticized material.…”

Section: Equipment and Controlsupporting

confidence: 82%

“…Stainless steel Mild steel (Gandra et al, 2012) Alloy steel -AISI 4140 (Kramer de Macedo et al, 2010) -AISI 8620 (Kramer de Macedo et al, 2010) Austenitic stainless steel -AISI 304 (Govardhan et al, 2012;Rafi et al, 2011a) -AISI 310 (Kramer de Macedo et al, 2010;Rafi et al, 2010b) -AISI 316L (Lambrineas and Jewsbury, 1992; Puli and Janaki Ram, 2012a) -AISI 321 (Lambrineas et al, 1990;Liu et al, 2009) Martensitic stainless steel -AISI 410 (Puli et al, 2011) -AISI 416 (Vitanov et al, 2001) -AISI 431 (Vitanov et al, 2001) -AISI 440 (Puli and Janaki Ram, 2012b) (Katayama et al, 2009) Tool steel -AISI O1 (Chandrasekaran et al, 1998;Chandrasekaran et al, 1997) -AISI D2 (Rao et al, 2012c) -AISI H13 (Rafi et al, 2010a(Rafi et al, , 2011c High speed steels -BM2, BT15, ASP30 (Bedford et al, 2001) Co-Cr based alloys -Stellite 6,12 (Rao et al, 2012a) (Bedford et al, 1995; Ni-Cr based alloys -Inconel 600 (Chandrasekaran et al, 1998;Chandrasekaran et al, 1997) Aluminium -AA1100 (Sugandhi and Ravishankar, 2012) -AA6061 (Batchelor et al, 1996) Titanium (Pure) (Chandrasekaran et al, 1997) Brass (Batchelor et al, 1996) Bronze (Kershenbaum, 1972;Kershenbaum and Averbukh, 1964) Copper (pure) (Rao et al, 2012c) not successful -Ti-6Al-4V (Beyer et al, 2003;Nicholas, 1993) NiAl Bronze (Hanke et al, 2011) Copper ( Magnesium (AZ91) (Nakama et al, 2008b) not successful…”

Section: Consumable Rods Substrates Carbon Steelmentioning

confidence: 99%

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Friction surfacing—A review

Gandra

Krohn

Miranda

et al. 2014

Journal of Materials Processing Technology

251

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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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Section: Equipment and Controlsupporting

confidence: 82%

Section: Consumable Rods Substrates Carbon Steelmentioning

confidence: 99%

Friction surfacing—A review

Gandra

Krohn

Miranda

et al. 2014

Journal of Materials Processing Technology

251

View full text Add to dashboard Cite

show abstract

“…2a. Similar observations were made by Prasad Rao et al [27] who also noticed a smooth surface in an unsuccessful attempt to deposit copper coatings on steel substrate. In the case of Fig.…”

Section: Initial Testingsupporting

confidence: 86%

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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“…In this zone, the temperature starts to increase and the material becomes plasticized. At the end of first zone, the oxide layers can be removed from the contacting surfaces leading to the formation of two novel surfaces [15]. The second zone is the initial deformation zone where the temperature increases higher.…”

Section: Temperature and Force Testsmentioning

confidence: 99%

Gradient composite coatings on AA5754 using friction stir process

Tosun

Özler

Özcan

2019

Surface Engineering

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In this paper, a substrate material (AA5754) was coated using a consumable rod/coating shaft (AA7075) as both a single layer and gradient layers by friction stir process. The order of the gradient coating process can be listed as; mixing the Al + TiC powders, pressing inside the consumable rod, sintering at certain temperatures and coating the substrate material surface with three overlapping layers at different reinforcement ratios. Microhardness and wear tests were performed to investigate the mechanical properties of the coatings. The microstructures of the coated materials have been examined by using optical microscope and SEM. The EDX and XRD analyses were also applied to the new-coated materials. The shaft rotational speed had a significant effect on the microstructure in the friction coating which was performed at single layer and in a powder-free fashion. The gradient ratio in gradient coatings had a considerable effect on the hardness and wear resistance.

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Tool steel and copper coatings by friction surfacing – A thermography study

Cited by 42 publications

References 15 publications

Friction surfacing—A review

Friction surfacing—A review

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

Gradient composite coatings on AA5754 using friction stir process

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