An experimental and theoretical investigation of thermo-mechanical issues in friction surfacing of Al–Mg aluminum alloys: material flow and residual stress

Material flow and residual stress distribution during friction surfacing of aluminum alloy AA5083 on aluminum alloy AA5052 substrate have been evaluated employing a three-dimensional model and the finite element software, ABAQUS, as well as experimental investigation. Based on the results, the nature of residual stress in the coating was tensile while getting compressive by straying away from the boundary of the coating. An increment in heat input per unit length of coating has caused a decrease in the maximum tensile residual stress albeit increasing the extent of the region with tensile residual stress. On the advancing side, the velocity vector was larger than the retreating side due to the larger velocity difference between rotating rod and substrate. Moreover, the velocity difference between advancing and retreating sides was much lower in sample with minimum heat input compared to a sample with maximum heat input.