Friction surfacing of aluminum alloys on Ti6Al4V - Investigation of process parameters, material deposition behavior and bonding mechanisms
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in: Surface and Coatings Technology, Jahrgang 503, 131985, 01.05.2025.
Publikation: Beiträge in Zeitschriften › Zeitschriftenaufsätze › Forschung › begutachtet
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TY - JOUR
T1 - Friction surfacing of aluminum alloys on Ti6Al4V - Investigation of process parameters, material deposition behavior and bonding mechanisms
AU - Hoffmann, Marius
AU - Roos, Arne
AU - Klusemann, Benjamin
N1 - Publisher Copyright: © 2025 The Authors
PY - 2025/5/1
Y1 - 2025/5/1
N2 - This study addresses a detailed investigation of friction surfacing (FS) process parameters for two materials with low metallurgical compatibility, i.e. Al and Ti, to achieve successful depositions, representing a very challenging task. The difference in suitable process parameters between two Al alloys onto Ti is highlighted. For instance, AA6082 requires higher rotational speeds than AA7050, resulting in higher process temperatures that lead to the formation of intermetallics with a thickness of about 0.3 μm at the interface. This indicates that diffusion is the main bonding mechanism for AA6082, while mainly mechanical interlocking contributes to bonding for AA7050. Additionally, AA6082 presents slightly thicker (∼240 μm) and wider (∼28 mm) layers than AA7050 (∼185 μm and ∼24 mm, respectively). Based on the experimental results, a new theory of material deposition is proposed for the dissimilar Al/Ti material combination, as a unique deposition behavior could be identified. The experiments show that material is deposited only in the peripheral areas of the stud, but not in the center, as typically seen in FS. Higher local process temperatures in the peripheral areas result in lower local flow stresses, which increase stud shearing and thus deposition of the plasticized stud material.
AB - This study addresses a detailed investigation of friction surfacing (FS) process parameters for two materials with low metallurgical compatibility, i.e. Al and Ti, to achieve successful depositions, representing a very challenging task. The difference in suitable process parameters between two Al alloys onto Ti is highlighted. For instance, AA6082 requires higher rotational speeds than AA7050, resulting in higher process temperatures that lead to the formation of intermetallics with a thickness of about 0.3 μm at the interface. This indicates that diffusion is the main bonding mechanism for AA6082, while mainly mechanical interlocking contributes to bonding for AA7050. Additionally, AA6082 presents slightly thicker (∼240 μm) and wider (∼28 mm) layers than AA7050 (∼185 μm and ∼24 mm, respectively). Based on the experimental results, a new theory of material deposition is proposed for the dissimilar Al/Ti material combination, as a unique deposition behavior could be identified. The experiments show that material is deposited only in the peripheral areas of the stud, but not in the center, as typically seen in FS. Higher local process temperatures in the peripheral areas result in lower local flow stresses, which increase stud shearing and thus deposition of the plasticized stud material.
KW - Bonding mechanism
KW - Diffusion
KW - Dissimilar aluminum–titanium joining
KW - Friction surfacing
KW - Material deposition theory
KW - Engineering
UR - http://www.scopus.com/inward/record.url?scp=86000538211&partnerID=8YFLogxK
U2 - 10.1016/j.surfcoat.2025.131985
DO - 10.1016/j.surfcoat.2025.131985
M3 - Journal articles
AN - SCOPUS:86000538211
VL - 503
JO - Surface and Coatings Technology
JF - Surface and Coatings Technology
SN - 0257-8972
M1 - 131985
ER -