Performance analysis and optimization of deposition of Aluminium on carbon steel by friction surfacing

Abstract

Increasing interest in many industrial applications has been acquired by friction newlinesurfacing (FS) such as automotive, farm machinery and restoration of deteriorated newlinerailway tracks, reconstruction of components at nuclear power plants with newlinedamage incurred by cracking stress corrosion. Generally, FS is a Method for newlinesolid-state joining, which could be joined in both similar and dissimilar materials newlinewithout reaching their melting temperature and produced a homogeneous and newlinefine-grained structure coating. Due to its lower expense and strong ease of newlineapplication, carbon steel continues to be one of the precious structural materials. newlineBut oxidation resistance is not very strong because of the formation of noncompact newlinestyle oxide layer on the surface, such as corrosion resistance. To improve newlinethe service properties of steel, a thin layer of aluminium deposition is very newlineappreciate. During aluminium coating, it will oxidize and form a compact oxide newlinelayer which shielding the substrate steel from properties like oxidation, corrosion, newlineetc. newlineIn this research work, the successful deposition of aluminium AA6063 over EN8 newlinecarbon steel was obtained by using a friction surfacing process. The deposition newlinewas carried out at the conventional approach (CAFS) and substrate preheating newlineapproach (SPHAFS) of friction surfacing at the temperature of 100°C, 200°C and newline300°C respectively. Coating geometry like coating thickness, coating width, newlineinterface temperature, and mechanical properties like hardness, tensile and bending newlinestrength was extensively studied. The result shows that the width of the coating newlineis increased by increasing both rotational speed and substrate temperature but the newlinemaximum width was achieved at the intermediate level of rotational speed. The newlineincrease in coating efficiency at a range of 3-7 % were seen at various samples newlineobtained from different substrate preheat temperature. A combination of high newlinesubstrate preheats temperature, axial force and rotational speed leads to very newlinevi newlinesevere plastic deformation of coating material which degrade