The effect of friction surfacing process parameters on coating structure and microhardness

Friction coating is a method used to improve surface properties, enhance corrosion resistance and repair worn surfaces. In this study, a low-carbon AISI 1010 substrate was friction coated with AISI 304 consumable rods using the powder-free, the sintering and the powder-laying methods, and the effects of coating parameters on coating structure and microhardness were investigated. Coatings made with sintered rods reinforced with TiC experienced flaming during the coating process, which prevented successful coating application. Micro-images showed that in coatings made with the powder-free method and with the powder-laying method by adding 100% B4C powder, the interface was completely mixed, while secondary phases formed in the substrate. In coatings made using the powder-laying method by adding 100% TiC and the sintering method by adding 3% B4C powder, powder accumulation was observed along the interface, and micro-voids formed in the coating. Powder-free coatings exhibited a microhardness value of 201 HV. In comparison, coatings reinforced with the powder-laying method by adding 100% 100% TiC showed a 40% increase, reaching 280 HV, while those reinforced with the powder-laying method by adding 100% B4C achieved the highest increase of 67%, reaching 337 HV.