Hybrid reinforced friction surfaced aluminium alloy 6082-T6 claddings on knurled mild steel 1018: role of boron carbide and molybdenum disulfide in bonding performance

Hybrid claddings were created by Friction surfacing (FS). Aluminum Alloy 6082-T6 served as the consumable material. It was reinforced with different proportions of boron carbide (B4C) and molybdenum disulfide (MoS2). MS1018 mild steel plates were coated. The study examined the influence of reinforcement ratios (95:5, 90:10, 85:15) on bonding quality, microstructure, hardness, and tribological performance. Macro and microstructural evaluations confirmed defect free metallurgical bonds with uniform reinforcement distribution.,Higher MoS2 levels promoted localized clustering. Micro-hardness testing revealed maximum strengthening near base fusion line. Wear studies highlighted the beneficial effect of MoS2 in coefficient of friction reduction. Amongst them, the 90:10 cladding was most balanced, combining higher hardness, lowest weight loss, and moderate Co-efficient of Friction (COF). Worn surface analysis confirmed transition from severe abrasive grooves at low MoS2 levels to smoother, lubricated surfaces at optimum reinforcement. Surface durability by hybrid FS coatings in structural and tribological applications as enhanced.