Constant Feed Research Articles

Method for Increasing the Energy Efficiency of the Gear Teeth Cutting Process by Smoothing the Cutting Force Variation

The energy efficiency in metal cutting is, sometimes, very low. Recent studies show that the energy consumed for detaching chips represents only about 15% of the total energy involved in material machining. The available solutions for energy optimization in cutting processes mentioned are the improvement of manufacturing equipment, the optimization of processes, and appropriate production scheduling. Already-performed research shows that to increase energy efficiency, the cutting force must be reduced, for example, by reducing the depth of the cut and by increasing the feed rate. However, this is applicable when the cutting force is quasi-constant during the process, which is not the case for gear teeth cutting when the cutting force significantly varies. The present paper proposes a new solution for energy efficiency increase in gear teeth cutting, namely, the smoothing of the cutting force variation during the machining process, by keeping the area of the detached chip section quasi-constant during the cutting process. This can be reached by replacing the constant rolling feed, currently used in gear teeth cutting, with a rolling feed that varies after an appropriate law. An algorithm dedicated to implementing this solution has been developed. It uses graphical modeling in CATIA to find the variation in the detached chip area. Original MatLab R2018a applications were developed (i) to identify the analytical form of the law that approximates this variation and (ii) to find the variation law of the feed during the rolling motion, if imposing a constant area of the detached chip. The algorithm was successfully applied in the cases of toothing with a rack tool (by slotting) and with a pinion cutter (by slotting and turning). A technical solution for method implementation in practice is also presented.

Kalibrasi Wire Feeder Flux Core Arc Welding (FCAW) Mengacu Pada Standar British Standard (BS) 7570:2000 Dan British Standard (BS) European Standard (EN) 50504:2008

In the fabrication industry, the welding process plays a crucial role in both engineering and repair production processes. Continuous use of welding machines can lead to a decline in their effectiveness. Suboptimal machines may produce low-quality products. A common issue encountered is the poor quality of welds, even when each step has been aligned with the Welding Procedure Specification (WPS). One source of this problem is the welding equipment itself. The objective of this study is to calibrate arc welding equipment to ensure it remains within machine standards. Calibration is performed in accordance with BS EN 50504:2008 and BS 7570:2000. The calibration focuses on measuring constant voltage and wire feed speed (WFS). The measurement results for WFS variation indicate that it does not exceed a 10% error margin. This suggests that the WFS complies with the established standards. Consequently, the Lincoln LN-25X wire feeder speed is ready for use in fabrication and production processes.

Effects of operational parameters on fuel gas production from DC-transferred arc plasma processing of sewage sludge

ABSTRACT In this work, a DC-transferred arc plasma reactor was used to investigate the influence of operating parameters on the process of gas production from sewage sludge treatment. By varying the operating temperature, feedstock feed rate and exhaust gas flow, the study aims to elucidate the physicochemical mechanisms during plasma treatment. The sewage sludge from the municipal wastewater treatment plant has an ash content of 40.5%, consisting mainly of Si, Al, Fe and Ca (>75%), and a complex organic fraction containing carbonyls, amines and amides. At a constant mass of feedstock (without feed rate), the gas produced by the plasma treatment was obtained with a maximum syngas fraction of 86% and a heating value of 10,000 kJ/m3, while the process operated at a constant sludge feed rate of 300 g/min increased the volumetric fraction of the syngas to 95% and the heating value to 12,000 kJ/m3.

Mathematical modeling and experimental analysis of the double-effect DCMD-heat pump integrated system

High energy consumption represents one of the hindrances in enabling large scale application of membrane distillation. In this work, experimental and simulation studies of a double-effect direct-contact membrane distillation integrated with a single-stage vapor-compression heat pump (DE-DCMD-HP) were carried out for concentrating tap water with the aim to evaluate the energy saving of the integrated system. It was found during our experiments that an auxiliary cooler must be added to remove the excess heat from HP to enable the integrated system to reach the steady-state condition. The temperature-heat flux plots were first utilized to analyze how HP and DE-DCMD affected each other and reveal their coupling mechanism. The simulation results showed that the increase in the first-effect feed inlet temperature, Tfi,1 and the flow rate, V caused the thermodynamic cycle line of refrigerant shift to higher temperature, which led to the increase of the input power of the compressor and the auxiliary cooler, ultimately affecting the water production mass rate, ṁd, the coefficient of performance, COP, the gain output ratio, GOR, and the specific energy consumption, SEC. The experimental and simulation results revealed that increasing Tfi,1 and V increased the permeate flux Nh and GOR and reduced the SEC. The performances for three different DCMD configurations were furthermore evaluated via experiments at constant feed temperature whereby the SEC decreased from 2168 kWh·t−1 for single-effect DCMD to 1085 kWh·t−1 for DE-DCMD to 257 kWh·t−1 for DE-DCMD-HP.

A Thermodynamic Analysis of a Proton Exchange Membrane Electrolyzer

A thermodynamic, first law analysis was conducted to understand the temperature of a proton exchange membrane electrolyzer when operated at a constant voltage and feed water flow rate. When using the electrolyzer voltage, current, liquid water feed rate and temperature, the electrolyzer operating temperature can be calculated. Heat losses can also be accounted for but are currently neglected. Carpet plots show the resulting electrolyzer temperature under varying conditions. The calculated temperatures are in very good agreement with measurements conducted in our laboratories.

A Thermodynamic Analysis of a Proton Exchange Membrane Electrolyzer

A thermodynamic, first law analysis was conducted to understand the temperature of a proton exchange membrane electrolyzer when operated at a constant voltage and feed water flow rate. When using the electrolyzer voltage, current, liquid water feed rate and temperature, the electrolyzer operating temperature can be calculated. Heat losses can also be accounted for but are currently neglected. Carpet plots show the resulting electrolyzer temperature under varying conditions. The calculated temperatures are in very good agreement with measurements conducted in our laboratories.

The Effect of Depth of Cut and Spindle Speed on Cutting Parallelism Results on Aluminum 6061 CNC TU-3A Retrofit Machine

Machining process is an important part of manufacturing to form and finish high-precision components. Milling is a commonly used technique, and the advancement of CNC technology has enabled precise and consistent production. This study evaluated the effect of spindle speed and depth of cut on the surface parallelism (µm) of aluminum 6061 using a TU-3A retrofit CNC milling machine. A quantitative experimental method with factorial design of experiments (DOE) was applied, testing spindle speeds of 600 RPM, 800 RPM, and 1000 RPM and depths of cut of 1.0 mm, 1.5 mm, and 2.0 mm, while maintaining constant feed rates of 48 mm/min, 64 mm/min, and 80 mm/min. The results showed that spindle speed had no significant impact on surface parallelism (µm) (P-value = 0.924), although higher speeds showed a trend of better results. In contrast, depth of cut significantly affects parallelism (µm) (P-value = 0.000), with greater depth improving surface quality (µm). In addition, the interaction between spindle speed and depth of cut is also significant (P-value = 0.002), indicating that the combination of higher spindle speed with lower depth of cut produces better results. These findings suggest optimal machining parameters to improve surface parallelism (µm) in aluminum milling operations.

Trajectory control strategy for multi-tool synchronous electrochemical machining of blisk channels

The blisk is a core component of an aero-engine, and electrochemical machining (ECM) is the primary method for its manufacture. Among several ECM methods for blisks, multi-tool synchronous machining is the most efficient and advantageous for machining channels. The allowance distribution of the blank after blisk channel machining directly influences the blade profile accuracy. This paper proposes a trajectory control strategy to homogenize the allowance distribution of the blisk channel in multi-tool ECM. The strategy includes the design of the three-dimensional space motion of the tool and blisk, as well as the regulated feed speed. The structural characteristics of the blisk channel and the principle of ECM allow for designing and optimizing the multi-dimensional trajectory. The electric field simulations elucidate the influence law of the three-axis feed speed on the side gap. An algorithm is adopted to iteratively optimize the speeds for different positions to realize multi-dimensional motion control and allowance homogenization. The proposed trajectory control strategy is applied to ECM experiments for the blisk channel. Compared with the constant feed speed mode, the regulated speed strategy reduces the maximum allowance difference between the convex (CV) profiles by 36.18% and that between the concave (CC) profiles by 37.73%. Subsequently, the one-time ECM of eight blisk channels was successfully realized. The average time for a single channel was 12.5 min, significantly improving the machining efficiency. In conclusion, the proposed method is effective and can be extended for synchronously machining various blisk types with twisted channels.

A Comparative Study of Dry Turning Performance of 4340 Alloy Steel with As-Received and Cryogenically Treated Coated Cermet Cutting Tools

Cryogenic treatment has been shown to significantly improve the cutting performance of inserts. Alloy steel grade 4340, renowned for its high impact and abrasion resistance, has extensive application in aircraft landing and high-power transmission gears. In this study, a comparative characterization (microhardness and XRD profile) and dry turning performance evaluation (turned surface roughness and insert wear) of alloy steel grade 4340 were performed using as-received and cryogenically treated coated cermet cutting inserts. The turning operation was carried out with various cutting velocities ( 55, 90, and 150 m/min) and a constant feed and cutting depth (0.111 mm/rev and 1 mm) under dry cutting conditions. The cryogenically treated insert obtained A reduced Ra value compared to untreated conditions at all cutting speeds. In addition, Ra value was reduced to a maximum of 29%. A lower level of insert wear and chip particle deposition at the cutting point was observed with cryo-treated inserts. Finally, it was revealed that the better machining characteristics in terms of reduced Ra values and insert wear with cryo-treated conditions were due to the enhanced wear resistance over the untreated conditions.

Enhancing L-asparagine Production Through In Vivo ATP Regeneration System Utilizing Glucose Metabolism of Escherichia coli.

L-asparaginase synthetase, an ATP-dependent enzyme, necessitates ATP for its catalytic activity. However, the integration of L-asparaginase synthetase into industrial processes is curtailed by the prohibitive cost of ATP. To address this limitation, this study explores the construction of an efficient ATP regeneration system using the glucose metabolism of Escherichia coli, synergistically coupled with L-asparaginase synthetase catalysis. The optimal conditions for L-asparagine yield were determined in shake flasks. A total of 2.7 g/L was the highest yield achieved under specific parameters, including 0.1 mol/L of substrate, 0.2 mol/L glucose, 0.01 mol/L MgCl2 at pH 7.5, a temperature of 37 °C, and agitation at 300 r/min over 12 h. The process was then scaled to a 3-L fermenter, optimizing the addition rates of the substrate and magnesium chloride, and employing a constant glucose feed of 10 g/L/h. The scale-up process led to a significant enhancement in the production of L-asparagine. The yield of L-asparagine was increased to 38.49 g/L after 20 h of conversion, and the molar conversion rate reached 29.16%. This strategy has proven to be effective in improving the efficiency of L-asparagine production. When compared to in vitro ATP regeneration methods, this in vivo approach showcased superior efficiency and reduced costs. These findings furnish pivotal insights that may propel the enzymatic synthesis of L-asparagine toward viable industrial application.

Implementation of a first-mill cane-feeding control strategy based on a cane-harvest system

The analysis of the extraction performance of three Colombian sugarcane factories revealed large variations in milling operations. Because more than 70% of the extraction occurs in the first mill, the chute level behavior was evaluated, and the coefficient of variation (CV) values were greater than 55%. This was mainly caused by the control strategy not being capable of mitigating the effect of processing different densities of sugarcane. This variability resulted from the frequent change between manual and mechanically harvested sugarcane. An in-line indicator was designed to determine the type of sugarcane; this was based on the electric current drawn by the cane leveller. In collaboration with factory A, a control strategy was designed that changes the velocity relationship of the conveyor belts depending on the sugarcane harvest type. The control strategy was also applied in the second factory (B), with only a 1.5 m high first-mill chute, which affects feeding stability, but dynamic current protection was added. This was based on PID controllers that manipulate conveyor velocity proportionally, reducing the chance that it would come to a halt, protecting the cane knives and shredder from electrical overload, and providing a more constant mill feed. The evaluation of the new control strategy was compared with the old control loops, increasing the overall extraction of 0.40 and 0.68% for factories A and B, respectively. Better stability was achieved in the first mill chute with a CV of approximately 30%, which was also reflected in the chute levels of the following mills. The new control strategy used the instruments and actuators already installed without any additional investments and can greatly improve the milling performance and, as a result, profitability.

Evaluation of different glycerol fed-batch strategies in a lab-scale bioreactor for the improved production of a novel engineered β-fructofuranosidase enzyme in Pichia pastoris

The β-fructofuranosidase enzyme from Aspergillus niger has been extensively used to commercially produce fructooligosaccharides from sucrose. In this study, the native and an engineered version of the β-fructofuranosidase enzyme were expressed in Pichia pastoris under control of the glyceraldehyde-3-phosphate dehydrogenase promoter, and production was evaluated in bioreactors using either dissolved oxygen (DO-stat) or constant feed fed-batch feeding strategies. The DO-stat cultivations produced lower biomass concentrations but this resulted in higher volumetric activity for both strains. The native enzyme produced the highest volumetric enzyme activity for both feeding strategies (20.8% and 13.5% higher than that achieved by the engineered enzyme, for DO-stat and constant feed, respectively). However, the constant feed cultivations produced higher biomass concentrations and higher volumetric productivity for both the native as well as engineered enzymes due to shorter process time requirements (59 h for constant feed and 155 h for DO-stat feed). Despite the DO-stat feeding strategy achieving a higher maximum enzyme activity, the constant feed strategy would be preferred for production of the β-fructofuranosidase enzyme using glycerol due to the many industrial advantages related to its enhanced volumetric enzyme productivity.

Performance Analysis of Helical Milling and Drilling Operations While Machining Carbon Fiber-Reinforced Aluminum Laminates

Being a difficult-to-cut material, Fiber Metal Laminates (FML) often pose challenges during conventional drilling and require judicious selection of machining parameters to ensure defect-free laminates that can serve reliably during their service lifetime. Helical milling is a promising technique for producing good-quality holes and is preferred over conventional drilling. The paper compares conventional drilling with the helical milling technique for producing holes in carbon fiber-reinforced aluminum laminates. The effect of machining parameters, such as cutting speed and axial feed, on the magnitude of cutting force and the machining temperature during conventional drilling as well as helical milling is studied. It was observed that the thrust force produced during machining reduces considerably during helical milling in comparison to conventional drilling at a constant axial feed rate. The highest machining temperature recorded for helical milling was much lower in comparison to the highest machining temperature measured during conventional drilling. The machining temperatures recorded during helical milling were well below the glass transition temperature of the epoxy used in carbon fiber prepreg, hence protecting the prepreg from thermal degradation during the hole-making process. The surface roughness of the holes produced by both techniques is measured, and the surface morphology of the drilled holes is analyzed using a scanning electron microscope. The surface roughness of the helical-milled holes was lower than that for holes produced by conventional drilling. Scanning electron microscope images provided insights into the interaction of the hole surface with the chips during the chip evacuation stage under different speeds and feed rates. The microhardness of the aluminum layers increased after processing holes using drilling and helical milling operations. The axial feed/axial pitch had minimal influence on the microhardness increase in comparison to the cutting speed.

Experimental investigations with machine learning techniques for understanding of erosion wear in advanced aluminum nanocomposites

This article addresses the significant challenge of erosion wear in aluminum composites, particularly in industries such as automotive, aerospace and energy, where sustained material performance is crucial. The study focuses on the experimental investigation of erosive wear characteristics exhibited by advanced aluminum nanocomposites, utilizing an air jet erosion wear test apparatus. The erosion wear tests were conducted using diverse parameters, such as angles (30°, 45°, 60° and 90°), air pressures (1–4 bar) and a fixed 600-s duration, maintaining a constant sand particle feed rate of 2.0 (g/min) and utilizing stand-off distances of 10, 15 and 20 mm. Surface assessments were conducted using field emission scanning electron microscopy (FE-SEM) and energy-dispersive X-ray spectroscopy (EDS). The results revealed observable specimen wear, particularly at a 45° angle, with wear rates decreasing at higher impingement angles and reaching a minimum at 90°. Notably, the Al-4 wt.%TiC nanocomposites exhibited a 25% improvement in wear resistance compared to the base alloy. Further analysis of eroded surfaces through (FE-SEM) revealed a mechanism involving micro-cutting, plowing and grain pull-out, attributing wear primarily to plastic deformation and crack formation. Evaluating erosive wear results through six machine learning (ML) models demonstrated that gradient boosting regression emerged as the most accurate, achieving an R2 value of 0.97. This highlights the effectiveness of ML in predicting erosion wear rates and offers insights for improving aluminum composite materials in demanding industrial applications.

Improving Machined Accuracy Under a Constant Feed Speed Vector at the End-Milling Point by Estimating Machining Force in Tool Approach

A five-axis machining center (5MC) is capable of synchronous control, which makes it a feasible tool for quickly and accurately machining complicated three-dimensional surfaces, such as propellers and hypoid gears. Recently, the necessity of improving both the machined shape accuracy and the machined surface roughness of free-form surfaces is growing. Therefore, in our previous study, we aimed to maintain the feed speed vector at the end-milling point by controlling two linear axes and a rotary axis of the 5MC to improve the quality of the machined surface. Additionally, we developed a method for maintaining the feed speed vector at the end-milling point by controlling the three axes of the 5MC to reduce the shape error of the machined workpieces (referred to as the shape error herein), considering the approach path of the tool determined via calculation. However, a high machining force at the start of the workpiece cutting was observed and the factor contributing to this phenomenon was not determined, although this phenomenon leads to a shape error to a certain degree according to the machining condition. In this study, the main objective is to suggest a method to reduce the machining force at the start of the workpiece cutting and shape error. Hence, we develop a theoretical method to estimate the machining force by using an instantaneous cutting force model, which considers the synchronized motion of two linear axes and a rotary axis of the 5MC. Subsequently, we determine the most suitable approach path of the tool considering the prediction of the machining force. The results of this study indicate that the machining force can be estimated by applying an instantaneous cutting force using the feed per tooth and machining angle, and that both a high machining force at the start of the workpiece cutting and shape error reduction can be realized by using the proposed approach path of the tool.

13 Impact of precision feeding during gestation on the productive career of sows over three reproductive parities

Abstract The aim of this study was to evaluate the impact of precision feeding during gestation on the career performances and longevity of sows, initially gilts, monitored over three successive reproductive cycles. Four isoenergetic treatments were compared: two conventional constant-concentration feeding strategies (0.53 % DIS Lys) with feed supply either constant (flat feeding; FF) or variable (bump feeding; BF), and two precision feeding strategies based on the InraPorc model applied considering either the mean weight by parity (PFP) or the individual weight of each sow at breeding (PFI). Four groups, representing 393 gilts, were followed from breeding to weaning over three cycles. Body weight and backfat depth were measured at breeding, 90 d of gestation, parturition, and weaning. Feed consumption was monitored daily. Litter variables were measured, including birth and weaning weight, mortality, and overall body weight gain. A mixed model was used to analyze differences between the four treatments using the sow as the experimental unit for performance analysis during the third reproductive cycles. For the analysis of the overall productive career over the three reproductive cycles, the performances of the two conventional strategies (with constant Lys DIS concentration feeding, CONV) were compared with the two precision feeding strategies (PF). During the third cycle, PFP and PFI sows had a lighter body weight at the beginning of gestation than the FF sows (P < 0.01), but increased their body weight gain during gestation (P < 0.001). Backfat loss in PFP and PFI sows during lactation was greater compared with BF sows (P = 0.05), FF sow being intermediate. PFP sows had a lower stillborn rate (P = 0.04) and tended to have less total piglet mortality (P = 0.06) than FF and BF sows. Over the three reproductive cycles, the stillborn rate and total piglet mortality were less in PF sows than in CONV sows (respectively -0.9 %; P = 0.02 and -1.5 %; P = 0.03). PF sows weaned more piglets during their three cycles than CONV sows did (+ 0.7; P = 0.03), with weaning litter weight gain also increasing for PF sows (+3.7 %; P = 0.02). The culling rate of gilts after three cycles did not differ significantly among treatments (P = 0.27), but tended to be greater for PF sows after one cycle (+4.9 %; P = 0.08). The results seem to show a lasting benefit of precision feeding for sows, with a decrease in piglet mortality during lactation, suggesting greater piglet viability without significantly decreasing sow longevity.

ELECTRODE WIRE FEEDER FOR MIG/MAG AND TIG WELDING PROCESSES

The electrode wire feeding mechanisms of welding machines are designed to transport the electrode wire from the spool to the welding zone at a constant, predetermined speed or at a speed that varies according to a given law. One of the most promising areas for improving arc welding and surfacing equipment is to control the transfer of electrode metal by pulsing the electrode wire. Therefore, the feeding mechanisms of welding machines must ensure compliance with the conditions of continuous feeding at a constant speed or pulsed feeding with an intermittent movement. The problem of forming pulses with the required parameters can be solved by feeding mechanisms with a vibration drive. The main advantage of such a technical solution is the ability to produce pulsed motion with controllable frequency and amplitude parameters. Due to the high resolution of movement and high dynamic properties in transient motion modes, vibration-driven feeding mechanisms are able to provide high accuracy of bar material feeding into the working area of technological equipment. The principle of operation of such a mechanism is based on the transformation of spatial vibrations into linear displacements. The analytical dependencies obtained in this work allow us to determine the parameters of electrode wire movement by the vibratory feeding mechanism. The proposed technical solution makes it possible to provide different movements of the wire along its axis, and changing the pulsation mode is made possible by adjusting the oscillation frequency of the drive.

Improvement of Machinability of Hardened Steel in Turning Operation Using Cryogenically Treated Cutting Tool

Hardened steels need special cutting tools like PCBN and ceramic to be machined. But these cutting tools aren’t cost-effective and require machine tool structures that are stiff and don’t let vibrations through. The current trend is to find other, less expensive ways to make these materials easier to work with. Cryo-treating cutting tools is an effective way to improve the way the tool materials work when they are cut. Cryogenically treated tungsten carbide inserts in dry turning operations were looked at in this study. For hard turning of hardened mild steel (48 HRC), the performance of cryogenically treated Tungsten Carbide (WC) inserts was compared with that of untreated inserts in terms of chip-tool interface temperature and surface roughness under dry cutting conditions. The cutting tool (Untreated and Treated), and cutting speed (375, 512, 706 rpm) were selected as experiment parameters at a constant feed rate of 0.0841mm/rev and depth of cut 1mm. The chip-tool interface temperature analysis results revealed that temperature increases with the increasing cutting velocities. A better surface finish can be found at a higher cutting speed. The lower value of Ra was found at 1.75 μm (without cryogenic treatment) and 1.05 μm (with cryogenic treatment) for cutting speed at 706 rpm.

Biological Removal of Zinc (II) by Fusarium solani under Different Modes of Operational Strategies: A Comparative Study

The goal of the current batch biosorption experiment was to determine how well Fusarium solani (isolated from soil) resting cells could remove zinc (II) from aqueous solution. With an increase in pH (up to pH 5.0) and an increase in initial zinc (II) concentration of up to 500 mg/L, the specific zinc (II) removal increases. By increasing biomass content from 2.5 to 5.5 g/L, the specific zinc (II) removal remained nearly constant. The investigations also utilised resting cells from various growth stages and at an initial zinc (II) concentration of 500 mg/L, the maximum specific zinc (II) uptake (51.7 mg/g) was accomplished (36 h old). The comparison of the results revealed that cells in a growing state (63.9 mg/g) can achieve the highest selective uptake. Hence, the uptake of zinc(II) under various operational strategies was only done with growing cells. The biological uptake of zinc (II) was then done in a fed batch mode of operation using Fusarium solani growing cells. Increased volume pulse feeding (IVPF) and constant volume pulse feeding (CVPF) were used to study the fed batch process and the impacts of these operational methods on biological performance were contrasted with those of a traditional batch process. According to batch experiments, at pH 5.0 and an initial zinc (II) ion concentration of 500 mg/l, the maximum specific zinc (II) removal was 63.9 mg/g. The maximal specific zinc (II) removal in the IVPF process was determined to be 45.47 mg/g and 33.58 mg/g, but the values in the CVPF process were 33.12 mg/g and 22.59 mg/g respectively for the first and second pulse feedings in both cases. The zinc (II) uptake found in prior investigations carried out by the current authors employing the continuous mode of operation was then compared with these results. The process could be run for a longer period of time with a maximum specific zinc (II) removal of 52.8 mg/g when operating in a continuous mode which was shown to be the optimal operational strategy.

Nickel-aluminide cladding on a steel substrate using dual wire arc additive manufacturing

In this study the nickel-aluminide intermetallic cladded on AISI 1010 steed using dual wire arc process. The nickel-aluminide is fabricated in situ through an arc provided by a gas tungsten arc welding process and changing aluminum wire feeding rate. The research findings reveal that at a constant Ni wire feeding rate of 450 mm/min, by decreasing the Al wire feeding rate lower than 800 mm/min, the instability of the melt pool prevents the formation of a uniform deposit on the substrate. Although deposition has been done at an Al wire feeding rate higher than 1600 mm/min, transverse cracks have formed in the clad layer. Increasing the aluminum wire feeding rate from 1000 to 1400 mm/min decreases the dendritic arm size from 9.2 ± 0.1 to 4.1 ± 0.3 μm. Although unreacted nickel is visible in the microstructure at the Al wire feeding rate of 1000 mm/min, at a high feeding rate (1400 mm/min), most of the microstructure contains AlNi and Ni3Al intermetallic compounds. With the rise in Al wire feeding rate from 1000 to 1400 mm/min, both yield strength and ultimate tensile strength increase from 521.45 ± 14.16 to 620.89 ± 16.08 MPa and from 762.11 ± 19.89 to 855.65 ± 21.54 MPa, respectively. Intriguingly, the clad layer's tensile toughness decreases from 26.51 ± 2.43 to 18.32 ± 2.56 MJ m−3. By increasing the wire feeding rate from 1000 to 1400 mm/min, the wear rate at room temperature, 500 °C, and 800 °C increases by 61.2, 45.7, and 44.3%, respectively.