Identification of suitable process parameters for friction surfacing of mild steel with AA6063 aluminium alloy

The present study is aimed at identifying suitable process parameters for friction surfacing of IS2062 mild steel with AA6063 aluminium alloy and obtain relationships between the input parameters and the process response that can be used for sound coating with adequate strength and ductility. Factorial experimental design technique was used to investigate and select the parameter combination to achieve adequate strength and ductility. Mechatrode rotational speed, axial load and substrate traverse speed were observed to be the most significant factors on the process response. Based on the results, it was observed that (i) lower axial load and traverse speed with high rotational speed and (ii) higher axial load and traverse speed with lower rotational speed produced sound coatings. It has also been observed that sound coatings could be obtained in a narrow set of parameter range as the substrate-coating materials are metallurgically incompatible and have propensity to form brittle intermetallics.