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.

Phanikumar Gandham

Department of Metallurgical and Materials Engineering

H. Khalid Rafi

K. Prasad Rao

Advancing side

Bottom layers

FRICTION SURFACING

MATERIAL TRANSFERS

METAL FLOW

RECIRCULATIONS

Retreating side

TUNGSTEN POWDERS

flow visualization

Friction

Tungsten

Coatings

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 A: Physical Metallurgy and Materials Science

A new additive manufacturing process, termed "friction freeform fabrication," has been recently proposed by the authors. One of the unique capabilities of the process is that it can facilitate fabrication of three-dimensional parts in materials that are difficult to fusion deposit. The current study is a striking demonstration of this, in which cylindrical samples of 40 mm height and 10 mm diameter were successfully produced in borated stainless steel ASTM 304B4, a material known to be very difficult to fusion weld or deposit. Microstructures and mechanical properties of these samples were investigated in detail and were compared to those of standard wrought-processed alloy 304B4 Grade B material. © 2013 ASM International.

Journal of Materials Engineering and Performance

Microstructures and properties of friction freeform fabricated borated stainless steel

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.

Corrosion Science

Corrosion performance of AISI 316L friction surfaced 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.

Surface and Coatings Technology

Microstructures and properties of friction surfaced coatings in AISI 440C martensitic stainless steel

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

Surface Engineering

Friction surfacing: novel technique for metal matrix composite coating on aluminium–silicon alloy

Journal	Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science
ISSN	10735623
Open Access	No