This work offers a fresh perspective on buttering, a technique often considered for fusion welding of dissimilar metals. For the first time, buttering was attempted in solid state using friction deposition. Using this new “friction buttering” technique, fusion welding of two different dissimilar metal pairs (austenitic stainless steel/borated stainless steel and Al-Cu-Mg/Al-Zn-Mg-Cu) was successfully demonstrated. The results show that friction buttering can simplify a tough dissimilar welding problem into a routine fusion welding task. © 2017, The Minerals, Metals & Materials Society and ASM International.

Ravi Sankar Kottada

Department of Metallurgical and Materials Engineering

Janaki Ram G D

G. M. Karthik

Austenitic stainless steel

DISSIMILAR METALS

Friction

tribology

Welding

AL-CU-MG

DISSIMILAR WELDING

Fusion welding

Stainless steel

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

Metallurgical and Materials Transactions B: Process Metallurgy and Materials Processing Science

Multi-layer friction deposits in nickel-based superalloy Inconel 718 were investigated for their heat-affected zone liquation cracking resistance. The friction deposits, owing to their fine-grained microstructure with a large number of subgrain boundaries and fine, uniformly distributed carbide particles, were found to exhibit superior liquation cracking resistance to standard wrought-processed alloy 718. Based on these findings, a new technique involving friction deposition of the base plates prior to fusion welding was proposed for overcoming liquation cracking. © 2017, The Minerals, Metals & Materials Society and ASM International.

Use of Friction Buttering for Overcoming HAZ Liquation Cracking

In the present work, a metal-metal composite consisting of aluminum-magnesium alloy AA5083 matrix and nanocrystalline CoCrFeNi high-entropy alloy reinforcement particles in 12 vol% was successfully friction deposited in multiple layers. The layer interfaces or the reinforcement/matrix interfaces showed no brittle intermetallic formation – thanks to the inert nature as well as the high strength and hardness of the high-entropy alloy reinforcement particles. The composite showed significantly higher tensile and compressive strengths as compared to standard wrought-processed alloy AA5083-H112 and offered a much better combination of strength and ductility when compared to conventional aluminum matrix composites reinforced with ceramic particles. The current study establishes friction deposition as a viable technique for additive manufacturing of novel high-performance composite materials. © 2016 Elsevier B.V.

Materials Science and Engineering A

Additive manufacturing of an aluminum matrix composite reinforced with nanocrystalline high-entropy alloy particles

Friction Freeform Fabrication is a new solid-state additive manufacturing process. The present investigation reports a detailed study on the prospects of this process for additive part fabrication in superalloy Inconel 718. Using a rotary friction welding machine and employing alloy 718 consumable rods in solution treated condition, cylindrical-shaped multi-layer friction deposits (10 mm diameter) were successfully produced. In the as-deposited condition, the deposits showed very fine grain size with no grain boundary δ phase. The deposits responded well to direct aging and showed satisfactory room-temperature tensile properties. However, their stress rupture performance was unsatisfactory because of their layered microstructure with very fine grain size and no grain boundary δ phase. The problem was overcome by heat treating the deposits first at 1353 K (1080 C) (for increasing the grain size) and then at 1223 K (950 C) (for precipitating the δ phase). Overall, the current study shows that Friction Freeform Fabrication is a very useful process for additive part fabrication in alloy 718. © 2013 The Minerals, Metals & Materials Society and ASM International.

Friction freeform fabrication of superalloy inconel 718: Prospects and problems

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

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

While martensitic stainless steel AISI 440C is an attractive material for wear protection in many industrial applications, it is difficult to realize satisfactory coatings in this material using conventional weld overlay processes. Friction surfacing, a promising solid-state process, can help in this regard. In the current study, alloy 440C coatings were successfully made on low carbon steel substrates using friction surfacing. Bend and shear tests on coated specimens indicated excellent coating/substrate bonding. Microstructures, corrosion behavior, and wear performance of these coatings were compared with standard heat treated alloy 440C bulk material. While friction surfaced coatings in alloy 440C exhibited superior corrosion resistance to standard heat treated alloy 440C bulk material, their wear resistance was found to be somewhat inferior. Apart from these studies, experiments were conducted to assess the potential of the process for wide area coverage. Studies show that it is possible to achieve well-bonded coatings consisting of multiple overlapping tracks with excellent inter-track bonding. Overall, the current study demonstrates that friction surfacing is a very useful process for producing wear resistant coatings in difficult-to-fusion-deposit materials such as alloy 440C martensitic stainless steel. © 2012 Elsevier B.V.

Journal	Data powered by TypesetMetallurgical and Materials Transactions B: Process Metallurgy and Materials Processing Science
Publisher	Data powered by TypesetSpringer Boston
ISSN	10735615
Open Access	No