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1. A Novel Approach to Friction Surfacing: Experimental Analysis of Deposition from Radial Surface of a Consumable Tool

   https://doi.org/10.3390/coatings10111016  

   Seidi, Ebrahim ; Miller, Scott F. ( November 2020 , Coatings)

   null (Ed.)

   The friction surfacing technique is an advanced method for creating coatings of various materials onto the surface of a similar or dissimilar material substrate. In this method, there is no external source of heat energy, and all the heat energy required in this method is generated by friction. In this paper, a novel method of friction surfacing from the side of the consumable tool is introduced. The most significant difference in this technique is that material transfer will occur from the radial surface of the consumable tool as opposed to the end of the tool as in conventional friction surfacing. In lateral friction surfacing, the side of the rotating consumable tool is pressed against the substrate surface, which generates frictional heating and shear forces at the interface between tool and substrate. A layer of tool material is transferred from the consumable rod to the substrate surface as the tool moves across. In this study, 6063 aluminum alloy and AISI 1018 carbon steel are used as the materials of consumable tool and substrate, respectively. The impact of process factors, surface roughness values, tool mass loss, and deposition thickness are discussed in detail. The experimental results of this study reveal that lateral friction surfacing produces a very smooth ultra-thin deposition with full coverage, with coating layers with roughness values in the order of 1 µm. Additionally, there is no flash formed in this technique which reduces material consumption. Moreover, temperatures at the interface between the consumable tool and workpiece were measured to be lower than for that in friction surfacing from the end of the tool, which is beneficial for the metallurgical characteristics of the deposited material. 

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2. CHARACTERIZATION OF LATERAL FRICTION SURFACED AA6063 COATINGS

   Seidi, E. ; Miller, S. ( October 2021 , International Mechanical Engineering Congress & Exposition)

   Friction surfacing is a solid-state metal deposition technique suitable for a wide range of metallic materials. This technique results in coatings on surfaces for joining purposes or surface modification applications such as wear and corrosion performance improvements. In this study, a novel approach in friction surfacing is utilized in which the consumable tool deposits material from its side instead of the end of the tool, which has been employed in conventional friction surfacing. Frictional heat enables plastic deformation, which results in the depositing of the consumable material on the substrate surface. The process is carried out at temperatures below the melting point of the consumable material, resulting in a solid-state deposition process. In the current study, scanning electron microscopy and energy dispersive spectroscopy have been employed for the characterization of the interfaces and coatings. The results of this study exhibited that there is no elemental diffusion between the tool and substrate materials at the interface, showing that the process temperature was low enough to prevent plasticizing of the substrate surface. 

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3. Corrosion Performance of Different Aluminum Alloy Deposits Fabricated by Lateral Friction Surfacing

   Relue, W. ; Seidi, E. ; Hihara, L. ; Miller, S. ( October 2021 , International Mechanical Engineering Congress & Exposition)

   Friction surfacing technique is a thermo-mechanical approach for metallic deposition, suitable for a broad range of materials and applications. Friction surfacing can be employed for various industrial purposes such as coating, welding, repairing defective parts, surface hardening, and improving corrosion performance. In this technique, frictional heat generated at the interface of the consumable tool and substrate results in a severe plastic deformation at the end of the rod, enabling the deposition of a consumable material on the substrate surface. In this investigation, a novel method in friction surfacing, lateral friction surfacing, is employed to deposit the aluminum coatings. In this novel approach, the side of the consumable tool is pressed against the surface of the substrate, and the material transfer happens from the lateral surface of the tool. This technique provides extremely thin and smooth deposits, which are more consistent compared to the conventional approach of friction surfacing. Moreover, this technique enables fabricating of deposits in lower temperatures, lessening the thermal impacts on the microstructures and mechanical properties of the deposits. In this investigation plates of 1018 mild steel were partially coated with various aluminum alloys and corroded in an accelerated corrosion test chamber. The corrosion performance of the partially coated sample was evaluated by mass loss measurement. It was found that AA5086 offered the most corrosion protection. After 13 cycles of GM9540P test, equivalent to approximately 3½ years exposure at a mild/moderate marine site in Hawaii, almost all of the deposited aluminum was consumed. 

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4. PREDICTIVE MODELING OF INORGANIC 3C-SiC FRICTION MATERIALS USING MOLECULAR DYNAMICS SIMULATION

   https://doi.org/10.1615/IntJMultCompEng.2022043612  

   Zhang, Yizhan ; LeNeave, Cortney ; Yi, Yun-Bo ( January 2023 , International Journal for Multiscale Computational Engineering)

   Metallic friction materials currently used in industry may adversely impact the environment. Substitutions for metals in friction materials, on the other hand, can introduce operational safety issues and other unforeseeable problems such as thermal-mechanical instabilities. In this work, a molecular dynamics model has been developed for investigating the effects of material composition, density, and surface asperities on the tribological properties of inorganic 3C-SiC under various contact conditions at the atomic level. Predictions on the following results have been made: (1) elastic modulus, (2) tensile strength, (3) thermal conductivity, and (4) friction coefficient. The research findings can help improve the design of metal-free friction materials against thermal-mechanical failures. Parametric studies were performed by varying a number of conditions including (1) ambient temperature, (2) sliding speed, (3) crystal orientation, (4) asperity size, (5) degree of asperity intersection, (6) types of loading, and (7) surface contact. Plastic deformation and material transfer were successfully modeled between two sliding pairs. Some of the computational results were validated against existing experimental data found in the literature. The evaluation of wear rate was also incorporated. The model can easily be extended to deal with other nonmetallic friction composites. 

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5. Friction Surfacing From Radial Surface of A6063 Aluminum Alloy Consumable Tool Onto A36 Carbon Steel

   Seidi, E. ; Miller, S. ( January 2020 , Proceedings of the ASME 2020 International Mechanical Engineering Congress and Exposition)

   Friction surfacing is an advanced technique to create solid-state deposition of wide range of materials onto a similar or dissimilar material substrate. This paper describes the study of a novel method to deposit material onto a substrate by friction surfacing. In the friction surfacing technique, the heat is generated entirely by friction. This metallic deposition technique consists of a rotating consumable tool that rubs against the surface of the substrate, and due to the frictional heat and forging generated between the tool and substrate, material is deposited onto the substrate. The material transferred from the consumable tool to the substrate occurs from the side of the tool, while in the conventional friction surfacing method, the material transfer happens from the end of the tool. In this investigation, the single and double-pass deposition of A6063 aluminum alloy onto an A36 carbon steel substrate was successfully carried out. To study the influence of the process parameters on the friction depositions, the substrate was divided into three sections, while the applying forces were varied in each section. Process parameters such as tool rotational speeds, table traverse speeds and normal force were experimented. A customized JET JMD-18 milling machine was used to carry out the experiments. The influence of process parameters on the material deposition was characterized by means of roughness tester and optical microscope. The results of the study reveal that this novel method is capable to create an ultra-thin and smooth metallic deposition with excellent coverage. The material consumption during the single and double-pass deposition was evaluated, and the coating cross-section was assessed using the optical microscope. 

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