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.

Krishnan Balasubramaniam

Department of Mechanical Engineering

Phanikumar Gandham

Department of Metallurgical and Materials Engineering

H. Khalid Rafi

K. Prasad Rao

Advancing side

FRICTION SURFACING

Higher temperatures

Retreating side

steady state

Thermal profiles

THERMAL PROFILING

VISCOUS HEAT DISSIPATION

Coatings

Friction

Friction welding

Thermography (temperature measurement)

THERMOGRAPHY (IMAGING)

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

In this work, we explore the possibility of utilizing friction surfacing, an emerging solid-state surface coating process, for layer-by-layer manufacture of three-dimensional metallic parts. One possibility in this regard (single-track friction surfacing) is to utilize friction surfacing for depositing a track or layer of material (sufficiently wide to cover the entire layer area), which is subsequently shaped to its corresponding slice counter using CNC machining. Another possibility (multi-track friction surfacing) is to generate a layer from multiple overlapping tracks of friction surfaced material, which is subsequently shaped as required using CNC machining. In the current work, sound multi-layered deposits in various ferrous materials were realized using friction surfacing in both single-and multi-track approaches. Samples with fully enclosed internal cavities and those consisting of different materials in different layers were also successfully produced. The deposits showed fine-grain wrought microstructures with excellent bonding between individual layers and tracks. Basic mechanical properties of these deposits were found to be at par with their standard processed wrought counterparts. Overall, the current work shows that it is possible to develop a uniquely capable new additive manufacturing process based on friction surfacing. © 2013 Taylor & Francis Group, LLC.

Materials and Manufacturing Processes

Use of friction surfacing for additive manufacturing

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

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

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.

Materials and Design

Characterization of D2 tool steel friction surfaced coatings over low carbon steel

Infrared thermography was used to record thermal profiles during friction surfacing. Thermal profiles for different sets of consumable rod/substrates (tool steel/steel; copper/steel and copper/copper) were recorded and analyzed. The thermal profiles showed distinct stages of plastic deformation with respect to temperature. The mechanism of bonding or no-bonding was discussed based on thermal profile data. It was found that a metallurgically bonded coating can be obtained if the flow stress of the plasticized material is comparable with the localized stress developed due to axial loading. © 2011 Elsevier B.V.All rights reserved.

Journal of Materials Processing Technology

Tool steel and copper coatings by friction surfacing - A thermography study

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.

Material flow visualization during 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.

Microstructural evolution during friction surfacing of tool steel H13

Corrosion Science

IR thermographic detection and characterization of hidden corrosion in metals: General analysis

Applied Physics A

IR thermography characterization of residual stress in plastically deformed metallic components

Optics & Laser Technology

Using infrared thermography in order to compare laser and hybrid (laser+MIG) welding processes

Thermal profiling using infrared thermography in friction surfacing

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