Friction surfacing is a solid-state coating process that uses plastic deformation to improve the efficiency of the core metallic pattern, resulting in fine-grained coatings with superior wear and corrosion properties. This article focuses on the development of inherently homogeneous, non-diluted coating of AISI316Ti stainless steel above EN8 and also encloses the empirical relationship for the prediction of bond strength (B_s), coating thickness (C_t), and coating width (C_w). The key individualities for bonding geometry were believed to be the process parameters such as rotational speed (rpm), traverse speed (mm/s), and axial load (kN). The effect of input parameters on the bond’s external dimensions and strength was investigated using a multi-objective optimization approach through experimentation. The bond’s strength improved as the coating thickness was reduced and the coating width was increased. The grain-refined coatings superimposing martensitic microstructure with no deposition of carbide particles added value to the metallurgical study using the scanning electron microscope.

In this study, a novel attempt was made to prevent corrosion on an EN8 medium carbon steel substrate by coating it with AISI 316 stainless steel using the friction surfacing method. The ram tensile test was conducted on the sample and...

In this study, a novel attempt has been made to deposit AA6061 aluminum alloy onto a mild steel (MS) substrate using a modified friction surfacing (FS) system. The effects of spindle speed, feed rate and plunging force on the coating quality were evaluated. The measurement is taken in three different zones of the deposited sample as starting zone (A), middle zone (B) and End zone (C). The microhardness testing, sliding wear analysis, microstructure analysis, surface morphology analysis, x-ray diffraction (XRD) and scanning electron microscopy analysis was performed in all three zones. The microhardness measured in the zone B is higher than zone A and zone C points. The wear analysis indicated les mass loss and friction coefficient in middle zone (B) comparing to zone A and C, respectively. The microstructural analysis revealed a more refined and homogeneous grain structure in the middle zone (B), attributed to stable heat input and uniform material flow during deposition. The starting zone (A) exhibited incomplete plastic deformation and weaker bonding, while the end zone (C) showed signs of thermal instability and reduced material consolidation. Surface morphology analysis confirmed smoother and more uniform coating characteristics in zone B, whereas zones A and C displayed irregularities, including surface defects and discontinuities. XRD analysis indicated the absence of deleterious intermetallic phases, with improved phase stability observed in the middle region due to optimal processing conditions. SEM analysis further validated the presence of a defect free, dense microstructure with enhanced metallurgical bonding in zone B, while minor porosity and microcracks were observed in zones A and C. The improved tribological performance in zone B is attributed to its higher hardness, refined microstructure, and strong interfacial bonding. These findings confirm FS as an effective technique for producing durable AA6061 coatings on MS for advanced engineering applications.