Friction drilling is a new trend of hole making process in which the frictional force between the tool and work material is used for hole making, by thrusting of the tool into the work material without chips formation as like conventional drilling. During friction drilling ductility of the material increases with heat, which causes the material to extrude on the front and backsides of the hole, which forms the boss and bush respectively on the work piece, so it provides the required projection for threading. The damage to the surface occurring during the hole making, takes place at high temperature, which could be monitored using thermography. By using this technique damages occur during manufacturing can be monitored and minimized. Due to high temperature during drilling various phenomena like thermal phase transition, plastic flow of material and extrusion may occur, which directly influences mechanical properties and may cause plastic material from the hole surface. Friction drilling is used for hole making process of aerospace, automotive, commercial and industrial products.

Titanium–silicon oxynitride sulfite (TiSiNOS) is a coating material that is deposited on H13 tool steel using the scalable pulsed power plasma (S3P) technique, where the coating deposition is a hybrid process consisting of a mix of sputtering and arc evaporation. The maximum hardness and coating thickness measured on TiSINOS-coated H13 tool steel are 38 GPa and 3.1 µm, respectively. After implementing the L₉ orthogonal array, nine samples were coated with TiSiNOS, which consists of the same properties. The nine coated and uncoated samples were tested separately based on the L₉ pattern to achieve accurate results. The experimental results indicate that the wear loss can be reduced by minimizing the load at 25 N even if the temperature rises to 250 °C. SEM analysis reveals that the uncoated sample has higher wear loss when compared with the coated samples, and material pullout is visible from the uncoated sample. Based on these results, it can be concluded that TiSINOS coating in H13 tool steel helps in improving the tool life during the drilling process. Taguchi was used in this research to evaluate the wear behavior. The data observed from the experiment were analyzed using the Minitab tool. The most crucial factor is to determine the effects of process parameters. A higher temperature influenced the wear behavior of the tool.

The wear characteristics of coated H13 tool steel and as-casted H13 tool steel in dry sliding conditions were investigated through a pin-on-disc tribometer, where the H13 steel is used as a pin and EN31 steel is used as disc material. The study was focused on evaluating the tribological behaviour by examining the friction characteristics, surface morphology and wear performance. Initially, to improve the hardness of the untreated (as-casted) H13 steel, the tempering process where carried out on the samples, which helped elevate the hardness from 38 to 55 HRC. The worn surface of the samples was analysed using atomic force microscopy (AFM). Among the four samples (as-casted, heat-treated, AlCrN coated and TiN coated) the as-casted samples were affected by oxidation and adhesive wear. The material loss measured for as-casted, heat-treated, AlCrN and TiN samples was 30.34, 7.85, 0.78 and 0.14 mg, respectively. The measured coefficient of friction was 0.541 for as-casted, 0.492 for the heat-treated, 0.48 for the AlCrN and 0.147 for the TiN sample. From the study, the major conclusion was that the TiN coating offers major wear protection and lower friction.

In the field of automobile industry, the emergent condition is to reduce the noise, emission etc. For reducing the same, a lot of studies are going on. In an IC engine, the inlet manifold is used for supplying energy and the exhaust manifold for exit of smoke after power stroke, a lot of surveys are going on recycling of exhaust gas and to save energy, temperature at the exhaust manifold is about 1200° F. It is a single pipe which collects all exhaust gases from all the cylinders. Cast iron is used for manufacturing the exhaust manifold, due to its unique properties. In the exhaust system, the exhaust manifold plays a vital role for safely sending away toxic gases, reducing noise and air pollution. During exhaust, high heat is dissipated; it is harmful for the environment. The main concern of this research article is to design an exhaust manifold and analyse the heat dissipation, mainly how much heat is dissipated and how to save energy. Heat produced has been entirely different, best coating can be used for further research. A detailed study is done in this research. Exhaust manifold modelling is done using the software Pro-E and Computational Fluid Dynamics is done by the software Ansys.

The objective of this study is to carry out a literature review on the effect of friction drilling parameters on the mechanical and metallurgical properties of materials. The friction drilling process uses heat generated by friction between the workpiece and the tool. In a single step, tool penetrates into the work material, forming a circular hole and forms bushing without generating chips. Bushing acts as a structural scaffold and guide to assemble sheet metal parts without the need for separate threaded parts. This review focuses on the basics of friction drilling, advantages, applications, metallurgical and mechanical properties of the tool and materials. Tools reviewed in this research are high speed steel (HSS) and AISI H13 chromium hot work steel. The study observes that coated friction drilling tool life is more than uncoated friction drilling tool. At higher spindle speed and feed rate, good quality hole is produced with maximum bushing height and better surface finish.