Friction-Stir-Surfacing (FSS) Process of Aluminum Alloy (AA6061) Coating Over Mild Steel (IS2062) Substrate

Friction-stir-surfacing (FSS) is an innovative solid-state joining process that offers significant advantages in coating applications. This study focuses on applying FSS to deposit an aluminum alloy (AA6061) coating onto a mild steel (IS2062) substrate. The primary objective is to study the possibility and effectiveness of FSS for creating a durable high-quality aluminum coating on mild steel. The goal of the present work remains to determine the best procedure variables for friction-stir surfacing (FSS) of an IS2062 mild steel (MS) substrate with AA6061 aluminum alloy. To create sound coatings with a respectable level of binding strength and ductility, the study aims to forecast the connection between effort process limits and production process responses. The nine factorial investigational proposal performance is cast-off to predict the most effective incorporation of input variables to investigate this. The utmost important influences on the development comeback are demonstrated to be the vertical weight, substrate cross rapidity, and consumable rod (consumable rod) rotating rapidity. The experimental results show that sound coatings can be generated at low axial loads, low bench traverse speeds, and high tool rotational speeds. Possible to create good sound coating were higher vertical loads and traverse speeds with low rotational speeds. Furthermore, the substrate’s coating material is metallurgically incompatible and has a propensity to produce intermetallic brittle phases at the interface zone. Additionally, it has been discovered that there is a finite range of process parameter values within which sound coatings can be created.