Influence of friction surfacing parameters on microstructure and mechanical properties of AA1050 overlaid by AA6061-T6

Motekallem, Mohammad Javad; Sarkari Khorrami, Mahmoud; Heydarzadeh Sohi, Mahmoud

doi:10.22059/jufgnsm.2026.01.03

Influence of friction surfacing parameters on microstructure and mechanical properties of AA1050 overlaid by AA6061-T6

Document Type : Research Paper

Authors

Mohammad Javad Motekallem

Mahmoud Sarkari Khorrami

Mahmoud Heydarzadeh Sohi

School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran

10.22059/jufgnsm.2026.01.03

Abstract

This study investigates the friction surfacing (FS) of AA6061-T6 consumable rods onto AA1050 commercially pure aluminium substrates, focusing on the effects of rotational speed (1250–2500 rpm) and travel speed (250–750 mm/min) on coating geometry, microstructure, bond strength, and hardness. The results show that increasing either rotational or travel speed reduces both coating thickness and width due to enhanced material flowability and heat generation. Bond strength improves at higher rotational and travel speeds, attributed to greater viscoplastic flow and interfacial bonding. Optimum processing conditions produced a heat-affected zone (HAZ) approximately 2 mm deep in the substrate, with the central region and advancing side experiencing the most intense thermal exposure and recrystallisation. The central region exhibited coarser recrystallised grains due to prolonged heat exposure, while insufficient bonding occurred locally on both sides due to inadequate compressive force and material flow. Microhardness measurements revealed a 15% reduction in substrate hardness, mainly within the HAZ. Although strain hardening and dynamic recrystallisation in the deposited layer partially offset softening, the loss of T6 temper led to an overall 8% hardness reduction compared to the consumable rod. These findings demonstrate that FS process parameters critically govern coating dimensions, interfacial integrity, and mechanical performance.

Keywords

Friction surfacing

Aluminum alloy

Consumable rod

Microstructure

Dynamic recrystallization

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