Friction surfacing is a novel solid-state surfacing process with several advantages over conventional weld overlay processes. In this work, the corrosion behavior of AISI 316L stainless steel coatings made using friction surfacing and manual metal arc welding processes was comparatively evaluated. Friction surfaced coatings exhibited superior general and pitting corrosion resistance compared to manual metal arc coatings, while both the coatings were found to be immune to intergranular corrosion. Compared to alloy 316L bulk material, friction surfaced coatings showed better pitting corrosion resistance, but considerably lower general corrosion resistance. © 2012 Elsevier Ltd.

Janaki Ram G D

Department of Metallurgical and Materials Engineering

AISI316L STAINLESS STEEL

Bulk materials

Corrosion behavior

Corrosion performance

FRICTION SURFACING

Intergranular corrosion

MANUAL METAL ARCS

SURFACING PROCESS

WELD OVERLAY

Electric arc welding

Friction

Friction welding

Pitting

Stainless steel

Textures

tribology

Welding

Corrosion resistance

IIT Madras is a public technical and research university located in Chennai, Tamil Nadu. Founded in 1959, it is recognised as an Institute of National Importance.

IIT Madras has been ranked as the top engineering institute in India for four years in a row by the National Institutional Ranking Framework of the MHRD

It currently offers undergraduate, postgraduate and research degrees across 16 disciplines in Engineering, Sciences, Humanities and Management. About 596 faculty belonging to science and engineering departments and centres of the Institute are engaged in teaching, research and industrial consultancy.

IIT Madras

Corrosion Science

Medium strength low alloy steel is an attractive material for naval and defence applications for its excellent mechanical properties. DMR 249A is extensively used for application of ship building for its superior mechanical properties but owes poor corrosion resistance. In order to overcome the corrosion problem, Weld overlay cladding is used as an effective technique which improves the strength and corrosion resistance but also helps in manufacturing lightweight structures. Aim is to combat the corrosion by weld overlay surface coating using conventional arc welding process and observe the dilution. In the current study, Weld overlay cladding on medium strength low alloy steel (DMR 249A) of 50mm thick is done using manual metal arc welding process (MMAW) with corrosion resistant austenitic stainless steel (308L) electrode. Two layers of coating were done one over the other (each 2mm thick). Weld overlay clads were characterized for metallographic studies to observe the microstructure changes using image analyzer attached to optical microscopy and scanning electron microscopy (SEM). Mechanical testing were carried out using micro vickers hardness tester andductility bend test using Universal Testing Machine (UTM). Pitting corrosion behaviour is determined by the potentio-dynamic polarization tests in acidic chloride environment. Inter Granular Corrosion (IGC) was performed in boiling copper sulphate solution as per ASTM A-262 for 15 hours duration. The present investigation established that microstructure studies revealed increase in δ-ferrite in the weld overlay cladding. Superior mechanical properties are observed in second overlay coating compared to first overlay coating and base metal. Pitting potential in second overlay coating is observed to be more positive when compared with first overlay coating due to increase in chromium content. IGC studies showed that first overlay coating with AISI 308L observed to be more sensitized and having more weight loss which tends to be highly susceptible than second layer coating. It is attributed to the formation of high amount of delta ferrite. © 2019 Elsevier Ltd.

Materials Today: Proceedings

Microstructure, mechanical and corrosion behaviour of weld overlay cladding of DMR 249A steel with AISI 308L

Friction deposition is one of the promising new techniques for additive manufacturing. In this work, an aluminum matrix composite reinforced with titanium particles was successfully friction deposited. The multi-layer composite friction deposits showed well-bonded layers, very fine grain size, and uniformly distributed titanium particles. While the reinforcement/matrix interfaces showed no reaction products, the layer interfaces showed thin intermetallic bands. These brittle intermetallic bands were found to strongly affect the ductility of the multi-layer composite friction deposits in the build direction. However, the composite friction deposits performed satisfactorily in compression tests as well as in single-layer tensile tests. © 2015 Elsevier B.V.

Materials Science and Engineering A

Friction deposition of titanium particle reinforced aluminum matrix composites

How microstructures evolve in heat-treatable aluminum alloys during multi-layer friction deposition is an intriguing question. The current work shows that the process invariably leads to overaging of strengthening precipitates in such materials as alloy 2014. The problem can be overcome using a solution treatment, but it can lead to other problems such as abnormal grain growth. Based on these findings, it appears that the benefits of friction deposition cannot be fully realized in heat-treatable aluminum alloys. © 2013 Elsevier Inc.

Materials Characterization

Microstructure evolution in aluminum alloy AA 2014 during multi-layer friction deposition

AISI 410 martensitic stainless steel coatings were produced on low carbon steel plates using friction surfacing and manual metal arc welding processes. Microstructure evolution in these coatings was investigated. Dry sliding pin-on-disk wear tests and electrochemical corrosion tests (Tafel and potentiodynamic anodic polarization) were conducted on friction surfaced coatings and manual metal arc coatings in as-deposited condition. Tests were also conducted on alloy 410 bulk material in hardened and tempered condition for comparison. Friction surfaced coatings, which contained a fully martensitic microstructure, showed comparable wear and corrosion resistance to alloy 410 bulk material. On the other hand, manual metal arc coatings, which contained significant amount of δ-ferrite, showed considerably lower hardness, pitting corrosion resistance, and wear resistance compared to friction surfaced coatings. © 2012 Elsevier B.V.

Surface and Coatings Technology

Wear and corrosion performance of AISI 410 martensitic stainless steel coatings produced using friction surfacing and manual metal arc welding

Friction surfacing involves complex thermo-mechanical phenomena. In this study, the nature of dynamic recrystallization in friction surfaced austenitic stainless steel AISI 316L coatings was investigated using electron backscattered diffraction and transmission electron microscopy. The results show that the alloy 316L undergoes discontinuous dynamic recrystallization under conditions of moderate Zener-Hollomon parameter during friction surfacing. © 2012 Elsevier Inc. All rights reserved.

Dynamic recrystallization in friction surfaced austenitic stainless steel coatings

Metal flow behavior within friction surfaced coating was studied using tungsten powder as a marker. The results show that the top and bottom layers within the coating exhibit distinct flow patterns. The transport of material takes an involute path, and the material transfer starts from the advancing side of the coating to the retreating side and terminates at the center. The recirculation of material occurs at the retreating side of the coating. © 2011 The Minerals, Metals &amp; Materials Society and ASM International.

Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science

Material flow visualization during friction surfacing

Infrared (IR) thermography was used to measure thermal profiles in the coating, consumable rod, and substrate during friction surfacing. A sudden raise followed by a steady state in thermal profile was observed and attributed to viscous heat dissipation during plastic deformation. The retreating side of the coating experienced higher temperature compared to the advancing side, indicating that the hot plasticized metal is carried from the advancing side to the retreating side. © 2011 The Minerals, Metals &amp; Materials Society and ASM International.

Thermal profiling using infrared thermography in friction surfacing

Coatings of AISI H13 tool steel were made on low carbon steel by friction surfacing. Detailed microstructural studies and microhardness tests were carried out on the coatings. Studies revealed defect-free coatings and sound metallurgical bonding between the coating and the substrate. In addition, mechanical interlocking on a very fine scale was observed to occur between the coating and the substrate. Coatings exhibited martensitic microstructure with fine grain size and with no carbide particles. Coatings in as-deposited condition showed very high hardness (58 HRC) compared to the mechtrode material in annealed condition (20 HRC). Based on these findings, microstructural evolution during friction surfacing of H13 tool steel is discussed. The current work shows that friction surfaced tool steel coatings are suitable for use in as-deposited condition. Further improvements in coating microstructure and properties are possible with appropriate post-surfacing heat treatment. © 2010 Elsevier Ltd.

Journal	Corrosion Science
ISSN	0010938X
Open Access	No