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.

Krishnan Balasubramaniam

Department of Mechanical Engineering

A. Veera Sreenu

M. N. Libin

AXIAL LOADING

COPPER COATINGS

FRICTION SURFACING

LOCALIZED STRESS

PLASTICIZED MATERIALS

Thermal profiles

Friction

Friction welding

Stress analysis

THERMOGRAPHY (IMAGING)

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

Journal of Materials Processing Technology

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

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

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.

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.

Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science

Thermal profiling using infrared thermography in friction surfacing

Tool steel H13 was friction surfaced on low carbon steel substrates. Mechtrode (consumable rod) rotational speed and substrate traverse speed were varied, keeping the axial force constant. The effects of process parameters on coating characteristics and integrity were evaluated. A process parameter window was developed for satisfactory deposition of tool steel coatings. Coating microstructures were examined using optical microscopy, scanning electron microscopy, and transmission electron microscopy. Microhardness tests, shear tests, and bend tests were conducted on coatings. The results show that coating width is a strong function of mechtrode rotational speed, while coating thickness is mainly dependent on substrate traverse speed. Lower mechtrode rotational speeds results in wider coatings, while higher substrate traverse speeds produce thinner coatings. Thinner coatings exhibit higher bond strength than thicker coatings. Coatings show no carbide particles, yet exhibit excellent hardness (above 600 HV) in as-deposited condition due to their martensitic microstructure. © 2010 Elsevier B.V.

Friction surfaced tool steel (H13) coatings on low carbon steel: A study on the effects of process parameters on coating characteristics and integrity

Friction surfacing is a novel solid state surface coating process with several advantages over conventional fusion welding based surfacing processes. In this work, austenitic stainless steel (AISI 310) and tool steel (H13) coatings were friction deposited on mild steel substrates for corrosion and wear protection, respectively. Microstructural studies were carried out by using optical and scanning electron microscopy. Shear tests and bend tests (ASTM A264) were conducted to assess the integrity of the coatings. This study brings out the microstructural features across the coating/substrate interface and its mechanical properties, showing good metallurgical bonding between stainless steel and tool steel coating over mild steel. © (2010) Trans Tech Publications.

Materials Science Forum

Microstructure and properties of friction surfaced stainless steel and tool steel coatings

Corrosion Science

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

Optics & Laser Technology

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

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

Journal	Journal of Materials Processing Technology
ISSN	09240136
Open Access	No