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1
Content available Investigation of multilayer coating of EN AW 6060 – T66 using friction surfacing
Krall Stephan, Baumann Christian, Agiwal Hemant, Bleicher Friedrich, Pfefferkorn Frank
Journal of Machine Engineering
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2022
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Vol. 22, No. 3
44--58
EN
The objective of this research is to investigate observable process changes during multi-layer friction surfacing of EN AW 6060 aluminum, whether for repair, remanufacturing, or new part manufacturing. In this study, friction surfacing was performed with a 10-mm-diameter rod of EN AW 6060 aluminum at spindle speeds ranging from 1000 to 7000 rpm to create up to three layers of 40-mm-long deposits on a substrate of the same alloy. The process forces and layer temperatures were observed. Post-process measurement of flash geometry, layer geometry and microhardness were conducted with the motivation to understand the impact of multi-layer depositions on performance and identifying acceptable conditions required to achieve acceptable build quality. The thickness, deposition and joining efficiency of layers in the multilayer configuration remained consistent. Friction surfacing of EN AW 6060 aluminum allowed for high deposition rates of 9 kg/hr, when compared to other metal additive technologies.
2
Content available remote Effect of friction surfacing parameters on the microstructural, mechanical properties, and wear characteristic of Al‑Cu‑Mg alloy coating reinforced by nickel aluminide
Farajollahi Ramezanali, Aval Hamed Jamshidi, Jamaati Roohollah
Archives of Civil and Mechanical Engineering
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2022
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Vol. 22, no. 2
art. no. e75, 1--18
EN
This research has studied the microstructure, mechanical properties, and tribological properties of AA2024-Al3NiCu composite coating fabricated by friction surfacing. The Al3NiCu intermetallic was created in the aluminum matrix by adding nickel during the stir casting process and then performing the homogenization treatment. The results showed that with increasing the axial feeding rate from 87.5 to 125 mm/min and the rotational speed from 600 to 800 rpm, the coating efficiency grew up to 79%. Moreover, no significant microstructural differences (grain size, precipitate size, and morphology) were observed in different parts of the coating. Applying the coating at a rotational speed of 800 rpm, a traverse speed of 125 mm/min, and an axial feeding rate of 125 mm/min raised the hardness and shear strength of the AA2024 aluminum alloy substrate by 17% and 21%, respectively, while lowering its wear rate by 37%.
3
Content available remote Characterization of microstructure, corrosion, and tribological properties of a multilayered friction surfaced Al–Mg–Si–Ag alloy
Pirhayati Parisa, Aval Hamed Jamshidi, Loureiro Altino
Archives of Civil and Mechanical Engineering
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2022
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Vol. 22, no. 4
art. no. e176, 2022
EN
In this research, an Al–Mg–Si–Ag multilayered coating with different amounts of silver additive was deposited on the AA2024 substrate using the friction surfacing process to investigate the microstructure, corrosion, and wear characteristics of the structure. The results showed that the silver-containing coating layer had a lower deposition rate and efficiency than coating without the silver additive. Owing to the lower temperature than silver-free coating and the presence of silver-rich particles acting as a barrier to grain boundary movement, no significant difference was found in grain size of different layers of the silver-containing coating. After aging heat treatment of the silver-containing coating, the Q (Al4(Cu, Ag) Mg4Si4) precipitates were formed as part of the silver-rich particles began to dissolve. After aging heat treatment, the top layer of the silver-containing coating showed 16% higher hardness than the AA2024 substrate. The wear rate of coating containing 13 wt% silver was 37% lower than the AA2024 substrate. The corrosion current density was reduced by approximately 97% and 99% in the silver-containing sample as compared to the sample devoid of silver and AA2024 substrate. With increasing silver content in the coated layer, the wear mechanism transitions from a combination of abrasive and adhesive wear mechanisms to an abrasive wear mechanism.
4
Content available Titanium metallization coating deposited on AlN ceramics substrate by means of friction surfacing process
Hudycz Michał
Welding Technology Review
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2020
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R. 92, nr 3
35--44
EN
The article characterizes a titanium metallization coating frictionally deposited on the surface of AlN ceramics. The method of preparing materials for metallization and the idea of the process were described. The results of stereometric tests of coating surfaces, metallographic tests and phase analysis are presented. Tests were carried out on the adhesion of the coating to the substrate and brazing tests of metallized ceramics with an FeNi42 alloy in an argon sheath using AgCu28 eutectic solder.
PL
W artykule scharakteryzowano metalizacyjną powłokę tytanową osadzoną tarciowo na powierzchni ceramiki AlN. Opisano sposób przygotowania materiałów do metalizacji oraz ideę procesu. Przedstawiono wyniki badań stereometrycznych powierzchni nakładanych powłok, badań metalograficznych, analizy fazowej. Wykonano próby przyczepności powłoki do podłoża i próby lutowania metalizowanej ceramiki ze stopem FeNi42 w osłonie argonu za pomocą eutektycznego lutu AgCu28.
5
Content available remote New approach of friction AlN ceramics metallization with the initial FEM verification
Cacko Robert, Chmielewski Tomasz, Hudycz Michał, Golański Dariusz
Archives of Civil and Mechanical Engineering
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2020
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Vol. 20, no. 3
385--395
EN
Although, the friction method is well known for metals surface modification, the novelty of the article is based on the new idea of ceramics surface treatment with metal. The paper describes AlN ceramic metallization process by titanium coating deposition, obtained in friction surfacing method, which has been developed by the authors. The friction energy is directly transformed into heat and delivered in a specified amount precisely to the joint being formed between the metallic layer and the ceramics substrate material. The stress and temperature fields (as factors promoting the formation of diffusion joints) induced in the joint during the metallization process were qualitatively determined with the finite element method analysis and these results were verified experimentally. Finally, obtained structures of the metallic coatings were investigated and the results are discussed in the paper. As a novelty it was found, that the conditions of frictional metallization can favour the formation of a coating-substrate bond based on diffusion phenomena and atomic bonds of the coating components with the components of the substrate, despite the fact that it happens for metal–ceramics pairs. This type of connection is usually associated with long-term heating/annealing in chamber furnaces, because for diffusion in a solid state the most effective factor is time and temperature. It was shown that other components of the chemical potential gradient, such as temperature gradient, gradient and stress level, load periodicity and configuration of pairs of elements with high chemical affinity may play an important role in friction metallization. As a result, the relatively short time of operation (friction) is compensated.
6
Content available remote Właściwości powierzchniowe i strukturalne tytanowej powłoki osadzanej tarciowo na podłożu ceramicznym AlN
Chmielewski Tomasz, Golański Dariusz, Hudycz Michał, Sałacinski Tadeusz, Świercz Rafał
Przemysł Chemiczny
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2019
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T. 98, nr 2
208--213
PL
Przedstawiono wybrane właściwości tytanowej powłoki metalizacyjnej wytworzonej na ceramice AIN metodą tarciową, opierając się na mechanizmie powstawania połączenia, w którym energia tarcia kinetycznego jest bezpośrednio zamieniana na ciepło i dostarczana w ściśle określonej ilości do powstającego połączenia między powłoką a podłożem. Opisano oryginalną metodę tarciowego osadzania cienkich powłok metalizacyjnych na ceramice i scharakteryzowano tytanową powłokę metalizacyjną pod względem budowy fazowej, właściwości metalograficznych, morfologii powierzchni, struktury stereometrycznej powierzchni oraz grubości.
EN
AlN ceramics was coated with Ti by friction-surfacing method where the energy of kinetic friction was directly transformed into heat and delivered in its sp. amt. directly to the formed joint between Ti layer and substrate material. The coating was studied for face structure, metallog. properties, morphol., stereostructure and thickness. The coating was 3-6 μm thick, defect-free and rough enough (0.404 and 1.95 μm) to be soldered to metals.
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