Combined experimental-numerical analysis of A356 aluminum alloy friction surfacing on AA2024 aluminum alloy substrate

This study examined the influence of the rotational speed of an A356 aluminum alloy consumable rod on thermo-mechanical issues, microstructure, and the wear resistance of coating during friction surfacing on an AA2024 aluminum alloy. The study utilized a comprehensive experimental-numerical analysis to fulfill its objectives. The findings reveal that the width and thickness of the coating increase by 7 and 18 % percent, respectively, as the rotational speed of the consumable rod is augmented from 600 to 800 revolutions per minute (rpm). A higher rotational speed of the consumable rod facilitates plastic deformation of the material within it, enabling softer material to be deposited on the substrate's surface under reduced axial force. Simulation outcomes display that the maximum plastic strain is experienced on the coating's upper surface, which contacts the tip of the consumable rod. Upon moving toward the interface between the coating and the substrate, the degree of plastic strain rapidly diminishes. In the coatings produced by rotational speeds of 600 and 800 rpm, a fine grain layer forms on the upper side of the coating that comes into contact with the consumable rod's tip. Friction surfacing utilizing a rotational speed of 800 rpm, a traverse speed of 125 mm/min, and an axial feeding rate of 100 mm/min, results in increases of 9 and 38 percent in hardness and wear resistance respectively, compared to the AA2024 substrate.