Mechanical and wear behavior of al-steel solid state cladding produced by friction stir surfacing

Abstract

Friction surfacing (FS) is a solid-state cladding method that produces a coating with minimum dilution and good metallurgical bonding. Deposition of aluminium over mild steel with using fusion based joining process is not feasible sue to the formation of iron aluminide and Fe and Al are metallurgically immiscible to each other. Hence, deposition of aluminium on steel with solid-state condition is feasible and most viable option. During the process, a rotating consumable rod is rubbed against the substrate plate under an applied axial load. The friction between rod and substrate generates a visco-plastic layer at the end of rod tip. The high temperature and pressure at interfaces aids in the cladding of the rod material on the substrate. Aluminium alloy 6351 T6 rod of 22 mm diameter was used as consumable material for surfacing on a 6mm thick SA516 Gr70 steel substrate plate. Optimized process parameters were used for the final experimental trials. Multilayer samples generated at constant Friction Surfacing variables were subjected to Pin-on-disc wear test at 40N load. Mechanical interlocking was also observed at the interface of the layers. The process was also observed to produce extremely fine grain microstructures of the deposited material due to the hot forging action involved resulting in superior wear properties.