Numerical and Experimental Investigation of Residual Stress and Bond Strength in Friction Surface Cladding Process

The bond strength is an essential property of cladded products, which are produced by deposition processes such as friction surface cladding (FSC). Friction and severe plastic deformation of the deposited material cause the process to take place at elevated temperatures, and inhomogeneous cooling af...

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Bibliographic Details
Published inJournal of materials engineering and performance Vol. 33; no. 8; pp. 3859 - 3870
Main Authors Naserinejad, K., Masoumi, A., Bor, T. C., Mashhadi, M. Mosavi
Format Journal Article
LanguageEnglish
Published New York Springer US 01.04.2024
Subjects
Characterization and Evaluation of Materials
Chemistry and Materials Science
Corrosion and Coatings
Engineering Design
Materials Science
Original Research Article
Quality Control
Reliability
Safety and Risk
Tribology
residual stress
bond strength
friction surface cladding
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Summary:The bond strength is an essential property of cladded products, which are produced by deposition processes such as friction surface cladding (FSC). Friction and severe plastic deformation of the deposited material cause the process to take place at elevated temperatures, and inhomogeneous cooling after the deposition process can lead to the formation of residual stresses that influence the remaining bond strength. A novel simulation method for the evaluation of the residual stress distribution in clad layer and substrate after the cladding of AA6060 onto an AA2024 substrate is proposed in this study. The effect of residual stresses on the bond strength was correlated with data gathered from 3-point bending tests aimed at the determination of the mechanical properties at the clad layer–substrate interface. The results show that on the one side, the occurrence of a higher compressive residual stress magnitude increases the bond strength, but on the other side, this relationship is not always true for average tool temperature, tool rotating speed, normal force, and tool tilt angle. Therefore, it is necessary to investigate the effect of average tool temperature, tool rotating speed, normal force, and tool tilt angle parameters on the residual stress to find the best process window for carrying out the process to have optimal bond strength.
ISSN:1059-9495
1544-1024
DOI:10.1007/s11665-023-09041-7