Optimization of Friction Surfacing Process Parameters for AA1100 Aluminum Alloy Coating with Mild Steel Substrate Using Response Surface Methodology (RSM) Technique

Abstract

Friction surfacing was attempted with aluminum on a mild steel substrate. This paper focuses on the development of empirical relationship for the prediction of coating width, coating thickness of friction surfaced materials. Experimental part of the study is based on five level central composite designs of three process parameters. In order to investigate the effects of input parameters on coating width and coating thickness, an empirical relationship is constructed by multiple regression analysis. Optimization of the model is carried out to study the coating width and thickness using design-expert software. Deposit geometry measurements for all the specimens space carried out and compared with the relative impact of input parameters on coating width and thickness in order to verify the measurement errors on the values of the uncertainty in estimated parameters. The results obtained show that the developed empirical relationship can be applied to estimate the effectiveness of process parameters for a given coating width and thickness.