Optimizing Deposition Parameters in Friction Surfacing of Al–Ni on Mild Steel

This study focused on the Friction Surfacing (FS) of Al7075–15Ni composite on Mild Steel Substrate (AISI 1018), and the subsequent process parameter were optimized through Taguchi's L9 orthogonal array design. Several distinct permutations of the parameters were investigated to determine their effect on coating quality, to determine the conditions that provide a uniform deposit free from defects, and to determine how the coating dimensions would be altered with changing processing parameters. The thermal behavior during FS was monitored through an instantaneous infrared thermometer by recording the interface temperature at 10-second time intervals. The EDS analysis on the coating deposit confirmed the presence of Fe-Al and Al-Ni intermetallics at the point where the FS layer meets the substrate. The intermixed substrate and coating elements at the contact zone provided a clear indication of diffusion in active mode, showing a strong metallurgical bond across the interface.