In this study, we investigated the impact of ageing heat treatment following friction surfacing of a solid solution-treated Al-16Si alloy on coating geometry, microstructure, and wear resistance. We employed a simulation using the smoothed-particle hydrodynamics (SPH) method alongside experimental analysis. The simulation results revealed that as the rotational speed increased from 600 to 1000 rpm, the coating efficiency decreased significantly from 31.2 to 13.1%. When comparing the coating to the substrate and the consumable rod, it was seen that after ageing heat treatment, the wear rate of the coating made at a rotational speed of 600 rpm dropped by a lot, by 70% compared to the substrate and by 53% compared to the consumable rod.
PadhyGKWuCSGaoS. Friction stir based welding and processing technologies - processes, parameters, microstructures and applications: a review. Journal of Materials Science & Technology2018; 34: 1–38.
2.
RahmatiZAvalHJNourouziS,et al.Microstructural, tribological, and texture analysis of friction surfaced Al-Mg-Cu clad on AA1050 alloy. C. Technology2020; 397: 125980.
3.
MirandaRMGandraJPVilacaP, et al.Surface modification by solid state processing. Sawston, Cambridge: Woodhead Publishing, 2013.
4.
RahmatiZJamshidi AvalHNourouziS,et al.Effect of mechtrode rotational speed on friction surfacing of AA2024 on AA1050 substrate. CIRP Journal of Manufacturing Science and Technology2021; 33: 209–221.
5.
FarajollahiRJamshidi AvalHJamaatiR, et al.Effects of pre- and post-friction surfacing heat treatment on microstructure and corrosion behavior of nickel-aluminide reinforced Al-Cu-Mg alloy. Journal of Alloys and Compounds2022; 906: 164211.
6.
PirhayatiPJamshidi AvalHLoureiroA. Characterization of microstructure, corrosion, and tribological properties of a multilayered friction surfaced Al–Mg–Si–Ag alloy. Archives of Civil and Mechanical Engineering2022; 22: 176.
7.
Jamshidi AvalH. Investigation of microstructure and tribological properties of titanium-aluminide reinforced aluminum matrix composite friction surfaced on AA1050 aluminum. Surface Topography: Metrology and Properties2022; 10: 045027.
8.
BararpourSMJamshidi AvalHJamaatiR. Combined experimental-numerical analysis of A356 aluminum alloy friction surfacing on AA2024 aluminum alloy substrate. Journal of Materials Research and Technology2023; 25: 4860–4875.
9.
BararpourSMJamshidi AvalHJamaatiR,et al.Investigation of the effect of traverse speed in friction surfacing of Al–16Si alloy by smoothed-particle hydrodynamics (SPH) simulation and experimental study. Computational Particle Mechanics2023. https://doi.org/10.1007/s40571-023-00626-6
10.
BararpourSMJamshidi AvalHJamaatiR,et al.Comparison of finite element and smoothed-particle hydrodynamics models in the simulation of hypereutectic Al-Si alloy friction surfacing: calibrations from experiments. Archives of Civil and Mechanical Engineering2023; 23: 224.
11.
MarodeRVPedapatiSRLemmaTA,et al.A review on numerical modelling techniques in friction stir processing: current and future perspective. Archives of Civil and Mechanical Engineering2023; 23: 154.
12.
TongM. Review of particle-based computational methods and their application in the computational modelling of welding, casting and additive manufacturing. Metals2023; 13: 1392.
13.
MarodeRVPedapatiSRLemmaTA,et al.Thermo-mechanical modelling of friction stir processing of AZ91 alloy: using smoothed-particle hydrodynamics. Lubricants2022; 10: 355.
ShishovaEPanzerFWerzM,et al.Reversible inter-particle bonding in SPH for improved simulation of friction stir welding. Computational Particle Mechanics2023; 10: 555–564.
16.
PirhayatiPJamshidi AvalH. Phase-field microstructure simulation during aluminum alloy friction surfacing. Surface and Coatings Technology2020; 402: 126496.
17.
PirhayatiPJamshidi AvalH. An investigation on thermo-mechanical and microstructural issues in friction surfacing of Al–Cu aluminum alloys. Materials Research Express2019; 6: 056550.
18.
RahmatiZJamshidi AvalHNourouziS,et al.Modeling and experimental study of friction surfacing of AA2024 alloy over AA1050 plates. Materials Research Express2019; 6: 0865g2.
19.
SchütteMREhrichJLinslerD,et al.Effects of microstructure modification by friction surfacing on wear behavior of Al alloys with different Si contents. Materials2022; 15: 1641.
20.
RahmatiZJamshidi AvalHNourouziS,et al.Effects of pre-heat treatment of the consumable rod on the microstructural and mechanical properties of the friction surfaced Al-Cu-Mg alloy over pure aluminum. Surface and Coatings Technology2021; 410: 126954.
21.
BararpourSMJamshidi AvalHJamaatiR,et al.Experimental and numerical investigation of Al16Si alloy friction surfacing on AA1050 aluminum substrate: effect of axial feeding rate. Surface and Coatings Technology2023; 468: 129778.
22.
ClearyPPrakashMHaJ. Novel applications of smoothed particle hydrodynamics (SPH) in metal forming. Journal of Materials Processing Technology2006; 177: 41–48.
23.
LindSJRogersBDStansbyPK. Review of smoothed particle hydrodynamics: towards converged Lagrangian flow modelling. Proceedings of the Royal Society A2020; 476: 20190801.
24.
ZhangCZhuY-jWuD, et al.Smoothed particle hydrodynamics: methodology development and recent achievement. Journal of Hydrodynamics2022; 34: 767–805.
25.
ShrivastavaPKumarPTandonP,et al.Improvement in formability and geometrical accuracy of incrementally formed AA1050 sheets by microstructure and texture reformation through preheating, and their FEA and experimental validation. Journal of the Brazilian Society of Mechanical Sciences and Engineering2018; 40: 1–15.
26.
BørvikTLangsethMHopperstadOS,et al.Ballistic penetration of steel plates. International Journal of Impact Engineering1999; 22: 855–886.
27.
RahamanMMPathakARoyD. A thermo-visco-plastic damage model and SPH simulations of plugging failure. Mechanics of Advanced Materials and Structures2018; 25: 1374–1382.
28.
DavisJR. Properties and selection: Nonferrous alloys and special-purpose materials. Materials Park, OH: ASM International Handbook Committee, 1990.
29.
DaviesJ. Aluminum and aluminum alloys. Materials Park, OH: ASM International, 1993.
30.
EskandariMJamshidi AvalHJamaatiR. The study of thermomechanical and microstructural issues in dissimilar FSW of AA6061 wrought and A390 cast alloys. Journal of Manufacturing Processes2019; 41: 168–176.
31.
George Sahaya NixonRMohantyBSSathishR. Friction surfacing of AISI 316 over mild steel: a characterisation study. Defence Technology2018; 14: 306–312.
32.
GuduruRKNagasekharAVScattergoodRO, et al.Thickness and clearance effects in shear punch testing. Advanced Engineering Materials2007; 9: 157–160.
33.
GandraJKrohnHMirandaRM, et al.Friction surfacing – A review. Journal of Materials Processing Technology2014; 214: 1062–1093.
34.
PirhayatiPJamshidi AvalH. Effect of silver on non-isothermal aging of friction surfaced AA2024-16 wt%Ag composites. Surface and Coatings Technology2019; 379: 125059.
35.
MohamadigangarajJNourouziSJamshidi AvalH. The effect of heat treatment and cooling conditions on friction stir processing of A390-10 wt% SiC aluminium matrix composite. Materials Chemistry and Physics2021; 263: 124423.
36.
MohamadigangarajJNourouziSAvalHJ. Microstructure, mechanical and tribological properties of A390/SiC composite produced by compocasting. Transactions of Nonferrous Metals Society of China2019; 29: 710–721.
37.
YousefpourFJamaatiRAvalHJ. Synergistic effects of hybrid (HA + Ag) particles and friction stir processing in the design of a high-strength magnesium matrix bio-nano composite with an appropriate texture for biomedical applications. Journal of the Mechanical Behavior of Biomedical Materials2022; 125: 104983.
38.
YousefpourFJamaatiRJamshidi AvalH. Investigation of microstructure, crystallographic texture, and mechanical behavior of magnesium-based nanocomposite fabricated via multi-pass FSP for biomedical applications. Journal of the Mechanical Behavior of Biomedical Materials2022; 125: 104894.
39.
AvalHJSerajzadehSKokabiAH. The influence of tool geometry on the thermo-mechanical and microstructural behaviour in friction stir welding of AA5086. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science2011; 225: 1–16.
40.
HumphreysFJHatherlyM. Recrystallization and related annealing phenomena. Oxford: Elsevier, 2012.
41.
RyenØHolmedalBNijsO, et al.Strengthening mechanisms in solid solution aluminum alloys. Metallurgical and Materials Transactions A2006; 37: 1999–2006.
42.
AshjariMFeiziAJ. 7xxx Aluminum alloys; strengthening mechanisms and heat treatment: a review. Material Science & Engineering International Journal2018; 2: 49–53.
43.
WyrzykowskiJGrabskiM. The Hall–Petch relation in aluminium and its dependence on the grain boundary structure. Philosophical Magazine A1986; 53: 505–520.
44.
FahmyARagaiA. Thermal-expansion behavior of two-phase solids. Journal of Applied Physics1970; 41: 5108–5111.
45.
TabriziATAghajaniHSaghafianH, et al.Correction of Archard equation for wear behavior of modified pure titanium. Tribology International2021; 155: 106772.
46.
KumarHPrasadRKumarP, et al.Friction stir welding of hypereutectic Al-Si alloy: Analysis of microstructure, mechanical and wear properties, AIP Conference Proceedings. Physics Ellipse College Park: AIP Publishing, 2023.
