Uncertainty Error Analysis on Micro Hardness of Al6061-B4C Surface Composites Produced by Friction Surfacing

Abstract

Friction surfacing is a confined surface modification process of depositing a layer of a consumable tool (Mechtrode) over the base plate (Substrate). This solid-state surfacing opts for dissimilar material and erosion resistant coatings. It is also utilized for localized repairing of worn-out components. In the present study, the hardness of the coated material is compared with the substrate. In this experiment, the Al-B4C composite consumable rod is prepared with Aluminium 6061 alloy and 3, 6, 9, 12 and 15 weight % of B4C by stir casting and coated over the Aluminium 6061 alloy plate. The 25-run experiment is conducted for the combination of the rotational speed, traverse speed and axial load. The combined effect of process parameters and the increase in weight % of B4C results in the change in hardness. The hardness of the coating is enhanced by 65% than the substrate. The uncertainty analysis revealed that it has a good correlation with the hardness standard value and also it has an error of 5%. The ANOVA analysis concluded that the rotational speed and the weight percentage of the reinforcement improved the microhardness of the coating.