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.

Janaki Ram G D

Department of Metallurgical and Materials Engineering

Phanikumar Gandham

H. Khalid Rafi

K. Prasad Rao

AISI H13

C. COATINGS

CARBIDE PARTICLES

COATING MICROSTRUCTURES

DEFECT FREE COATINGS

E. WEAR

F. MICROSTRUCTURE

Fine grains

FRICTION SURFACING

H13 TOOL STEEL

HIGH HARDNESS

MARTENSITIC MICROSTRUCTURE

MECHANICAL INTERLOCKING

METALLURGICAL BONDING

Micro-structural

MICROHARDNESS TESTS

STEEL COATINGS

Carbides

Friction

Friction welding

Low carbon steel

Microstructural evolution

Tool steel

tribology

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

Materials and Design

This work reports a feasibility study on producing friction surfaced coatings on nonferrous substrates. Commercially pure aluminum, copper, magnesium (ZM21), Inconel 800, and titanium alloy (Ti-6Al-4 V) were chosen as the substrates. Low carbon steel, aluminum alloy (AA6063), commercially pure copper and titanium were chosen as the consumable rods. Friction surfacing was attempted with all consumable rods on every substrate. In some cases metallur-gically bonded coating was obtained readily over the substrate and in some other cases coating was obtained with a start-up plate. However, for certain combination of parameters, no coating could be obtained. The coatings obtained were analyzed for their microstructural features and interfacial characteristics using optical and scanning electron microscopy. The results showed that co-efficient of friction, material properties like thermal conductivity, and stability at high temperature influenced the formation of a coating. Coatings obtained exhibited fine grained microstructure with properties better than the original parent material. Dynamic recrystalization as a result of severe plastic deformation accounts for grain refinement. © Springer-Verlag London Limited 2012.

International Journal of Advanced Manufacturing Technology

Friction surfacing on nonferrous substrates: A feasibility study

In this work D2 tool steel coating is produced over a low carbon steel substrate using friction surfacing process. The process parameters are optimized to get a defect free coating. Microstructural characterization is carried out using optical microscopy, scanning electron microscopy and X-ray diffraction. Infrared thermography is used to measure the thermal profile during friction surfacing of D2 steel. Wear performance of the coating is studied using Pin-on-Disk wear tests. A lower rotational speed of the consumable rod and higher translational speed of the substrate is found to result in thinner coatings. Friction surfaced D2 steel coating showed fine-grained martensitic microstructure compared to the as-received consumable rod which showed predominantly ferrite microstructure. Refinement of carbides in the coating is observed due to the stirring action of the process. The infrared thermography studies showed the peak temperature attained by the D2 coating to be about 1200. °C. The combined effect of martensitic microstructure and refined carbides resulted in higher hardness and wear resistance of the coating. © 2013 Elsevier Ltd.

Characterization of D2 tool steel friction surfaced coatings over low carbon 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

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.

Materials Characterization

Dynamic recrystallization in friction surfaced austenitic stainless steel coatings

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

Surface Engineering

Friction surfacing of titanium alloy with aluminium metal matrix composite

Evaluation of microstructure and mechanical properties in friction stir processed SKD61 tool steel

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

Journal	Materials and Design
ISSN	02641275
Open Access	No