Friction surfacing (FS) is a solid-state process employed for coatings that has demonstrated significant advancements in the manufacturing of aluminium matrix composites reinforced with ceramic particles. This study explores the effect of AA2017 aluminium consumable rods packed with titanium carbide (TiC) in the FS process applied to an AA6082 substrate. A subsequent post-processing friction stir process (FSP) was performed to further refine the distribution of ceramic particles. Analyses were conducted using light optical and scanning electron microscopy, X-ray diffractometer (XRD), microhardness, and pin-on-flat wear testing. The results demonstrated that the incorporation of TiC reinforcement significantly enhanced the FS deposition efficiency and rate by approximately 31%, without affecting rod consumption. Initially, the TiC particles were distributed in layers parallel to the substrate surface, but the FSP technique dispersed them throughout the aluminium matrix. In terms of mechanical properties, the reinforcement increased microhardness by 13.6% and reduced wear resistance (wear volume) by 13%. Notably, the FSP process enhanced wear resistance, reducing wear volume by 48% compared to the TiC-free coating, while also mitigating the hardness increase caused by the FS process. Additionally, XRD analysis indicated that neither FS nor FSP generated new phases, indicating no interaction between the aluminium matrix and the ceramic reinforcements.

The demand for electric mobility has driven the development of advanced laser welding technologies such as dual beam welding and beam shaping. Nevertheless, some intrinsic characteristics present challenges to exploring all its benefits. In this sense, this study investigates the effect of the laser welding parameters employed on the weld quality in busbar–battery interconnects. Dual beam and beam shaping strategies were applied in Al-Al (AA1050 H24) and Al-Cu (AA1050 H24 and C11000) overlap joint configurations adopting statistical methods. For Al-Al joints, welding speed was the most significant parameter influencing interface width, whereas in Al-Cu joints, core power was the only significant parameter affecting both interface width and penetration in the studied configuration. Common defects, such as porosity and cracks, were observed in both material combinations. In Al-Al joints, higher welding speeds resulted in up to a 16% (65.6 HV) increase in hardness, while, in Al-Cu joints, the peak value reached around 900 HV in the interface zone due to the formation of intermetallic compounds (IMCs). In addition, IMCs with complex structures and significant compositional variations, including Cu₉Al₄ and CuAl₂ were identified.

Repairing links of offshore mooring chains has presented a significant industry challenge, primarily arising from modifications in material properties, encompassing alterations in microstructure, hardness, and residual stress. In this context, the present work investigates the method of friction hydro-pillar processing (FHPP) applied to R4 grade mooring chain steel. Joints in as-repaired and post-weld heat treatment (PWHT) conditions were subjected to residual stress (RS) tests using the neutron diffraction technique, microhardness mapping, and microstructural evaluations. The process generated peaks of tensile and compressive stresses in different directions and hardness below that of the parent material in the softening zone. The friction zone promoted high hardness levels in the thermo-mechanically affected zone (TMAZ) with a maximum of 19% of the ultimate tensile strength of the parent material. As expected, the PWHT restored the RS and reduced the hardness; however, 4 h PWHT allowed the elimination of a hardness higher than that of the base material.

Friction Surfacing (FS) is a solid-state process employed for coatings that has demonstrated advancements in manufacturing aluminium matrix composites with ceramic particle reinforcements. This study explored the effect of AA2017 aluminium rods packed with TiC in the FS process and the subsequent post-processing Friction Stir Process (FSP). The analyses were carried out by light optical and scanning electron microscope, X-ray diffractometer (XRD), microhardness, and pin-on-flat wear testing. Therefore, the reinforcement significantly enhanced the FS deposition efficiency and rate (about 31%) without affecting rod consumption. It also increased the microhardness (13.6%) and the wear resistance (13% wear volume reduction) with particles spread in layers. However, the FSP thermomechanical processes modified this morphology and generated concentrated particle lines in the upper zone. It improved the wear resistance (48% wear volume reduction) compared with free-TiC coating and relieved the previous reinforcement coating hardness. In addition, the XRD analyses revealed that both processes hardly generated new phases, indicating no interaction between the matrix and the reinforcements.