Inductive heating effects on friction surfacing of stainless steel onto an aluminium substrate

An experimental setup was designed to compare the principal process parametric relationships with the classical approach to friction surfacing with the addition of inductive heating. The production of the flash is described quantitatively and its influence on coating geometry and mass is presented. It was found that the coating mass and thickness decreased for an increase in the rotational speed of the consumable rod; the amount of flash produced by the consumable rod also increased. However, the effect of an increase in this rod contact pressure on the coating thickness is insignificant, whilst the coating mass decreases with rising pressure and the coating width increases coupled with an increase in flash production. Cross sections showed good bonding quality and mechanical interlocking at the bond interface. The substrate-coating interface showed a varying degree of mechanical interlocking and the presence of cavitations. Bond strength values applying shear and push-off testing of up to 106 MPa and 96 MPa, respectively, could be identified.