Characteristics of Friction Surfacing Deposit and its Potential Application for Aluminum Spot Lap Joint
Keywords:
Friction surfacing, Surface roughness, Bending strength, Aluminum deposit, Aluminum lap jointAbstract
Friction surfacing is a solid-state surface modification technique capable of producing aluminum deposits with robust metallurgical bonding while reducing thermal degradation of the substrate compared to fusion-based coating methods. Nonetheless, the combined influence of consumable rod diameter and substrate surface roughness on layer formation, mechanical performance, thermal behavior, and potential application as mechanical joints remains inadequately understood. This study examines the effects of rod diameter and substrate surface roughness on aluminum layers produced by friction surfacing and assesses their suitability for aluminum spot-joint applications. AA6061 aluminum alloy served as the consumable rod, while AA1100 was utilized as the substrate. The process was executed at a rotational speed of 3300 rpm and a translational speed of 9 mm/min, with variations in rod diameter and axial load. Characterization involved measurements of bending strength, microhardness, and surface roughness. The results indicated that a 12 mm rod diameter combined with a 25 kg load yielded the highest bending strength of 203.48 MPa, attributed to stable material flow and balanced heat distribution. A lower substrate surface roughness (Ra = 1.070 µm) enhanced bending strength and hardness and facilitated a more uniform thermal distribution during deposition. Conversely, higher surface roughness accelerated heat generation and induced local stress concentrations, thereby diminishing the mechanical performance of the layer. These findings elucidate the relationship between process parameters, surface conditions, and mechanical properties in friction surfacing, demonstrating its potential for aluminum spot-joint formation through deposit formation and flash-based mechanical interlocking mechanisms.
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