Experimental Study and Thermo-Mechanical Simulation of Friction Surfacing Treated A390 Aluminum Alloy

In this study, the friction surfacing of Al-16Si alloy on AA1050 substrate was investigated using experimental and smoothed-particle hydrodynamics simulation methods. The effect of Al-16Si rod rotational speed on microstructure, surface roughness, mechanical properties, and wear resistance of coatings was examined. Both experiment and simulation findings show that by enhancing the rotational speed from 600 to 1000 rpm while reducing the effective width and thickness of the deposited layer, the deposited layer's efficiency decreases from 41 to 14%. By increasing the rotational speed from 600 to 1000 rpm, the interface roughness and surface roughness decreases to 78 and 80%, respectively. According to experiment and simulation results, plastic strain's influence on the grain size is dominant at a high rotational speed (1000 rpm), and by decreasing the rotational speed down to 600 rpm, the effect of temperature is dominant. In addition, the distribution of CuAl2 and silicon particles become more uniform with a decrease in the rotational speed from 1000 to 600 rpm, and the average size of these particles decreases to 0.62 and 4.35 mu m, respectively. Compared to the pure aluminum substrate, surfacing with a rotational speed of 600 rpm increases hardness, shear strength, and wear resistance by 224%, 265%, and 60%, respectively.