Optimization of coating thickness and coating width for friction surfaced Al6061-B4C over Al6061

Abstract

Friction surfacing is a surface composite fabrication method performed by coating a layer of mechatrode on the substrate. It is a solid-state coating processes used mainly for protecting the surface from wear, corrosion and also to repair the damaged surfaces or worn-out parts. In this investigation Al 6061-B4C composite consumable tool was coated over the Al 6061 substrate. The composite consumable tool was fabricated by stir casting process with Al6061 reinforced with weight percentage of B4C 0, 3, 6, 9 and 12. Based on the Taguchi method a 25-run was experiments performed. Four parameters and 3 levels were considered for investigation. The parameters considered for investigation are weight % of B4C, rotational speed, traverse speed and axial load. The output parameters measured are coating thickness and coating width. Uncertainty analysis (standard JCGM 100:2008 (Type ‘A’)) was performed for the measured value to ensure precision. And in addition, grey relational analysis was used to optimize coating thickness and coating width with the condition smaller the better. From the uncertainty error analysis, it was observed that the precision of both coating thickness and coating width was less than 5%. It can be observed from the results that for process parameters weight % of B4C, rotational speed, traverse speed and axial load both coating thickness and coating width were predicted to be 2.7 mm and 19.05 mm.