Friction surfacing of AA7075-T6 deposition on AA2024-T351; Statistical modeling using response surface methodology

In this research, deposition of AA7075-T6 coatings on AA2024-T351 substrates was studied. In order to investigate the influence of process parameters on the mechanical properties and microstructure, the experiments were performed based on design of experiments using Response Surface Methodology (RSM). Rotational speed (1200-1600 rpm), axial force (320-640 Kg) and feed rate (100-300 mm/min) were considered as input parameters, while coating width (w), coating thickness (t) and hardness of coating (HC), were raised as process outputs. The results reveal that joining of these two materials was done without any porosity at the interface. Hardness of coating showed a 30% decrease compared to the consumable rod in average. Thickness of deposition is decreased by increasing rotational speed, feed rate and axial force. If axial force is excessively increased, it results in development of an arc toward the plate along deposition. Microstructure of deposition turned into a totally fine-grained homogeneous structure in comparison with rod and plate microstructure.