Process parameter effects in the friction surfacing of MONEL over mild steel

MONEL has very good corrosion resistance and is used for cladding marine components. However, to avoid hot cracking, nickel is first overlayed on the substrate before MONEL is overlayed. Friction surfacing (FS) is a new solid state technique that could be used to do the same cladding process without any nickel overlay. In this study, MONEL K500 was deposited on AISI 1012 substrate using FS. Three parameters namely the spindle speed, axial load and the horizontal feed rate were varied at five levels and FS trials were conducted. Thickness of the coatings was measured for all the surfacing trials. Response surface methodology is utilized to develop a mathematical model for the thickness of the surfaced layer in terms of the three chosen parameters. The significance of the spindle speed, axial load and the horizontal feed rate in producing coatings with good bond integrity is investigated.