Optimizing Deposition Parameters in Friction Surfacing of Al–Ni on Mild Steel

International Journal of Mechanical Engineering

© 2026 by SSRG - IJME Journal

Volume 13 Issue 2

Year of Publication : 2026

Authors : Vinodh Sivalingam, Pradeep R, Gowtham S, Mallireddy Naresh

10.14445/23488360/IJME-V13I2P103

How to Cite?

Vinodh Sivalingam, Pradeep R, Gowtham S, Mallireddy Naresh, "Optimizing Deposition Parameters in Friction Surfacing of Al–Ni on Mild Steel," SSRG International Journal of Mechanical Engineering, vol. 13,  no. 2, pp. 22-32, 2026. Crossref, https://doi.org/10.14445/23488360/IJME-V13I2P103

Abstract:

This study focused on the Friction Surfacing (FS) of Al7075–15Ni composite on Mild Steel Substrate (AISI 1018), and the subsequent process parameter were optimized through Taguchi's L9 orthogonal array design. Several distinct permutations of the parameters were investigated to determine their effect on coating quality, to determine the conditions that provide a uniform deposit free from defects, and to determine how the coating dimensions would be altered with changing processing parameters. The thermal behavior during FS was monitored through an instantaneous infrared thermometer by recording the interface temperature at 10-second time intervals. The EDS analysis on the coating deposit confirmed the presence of Fe-Al and Al-Ni intermetallics at the point where the FS layer meets the substrate. The intermixed substrate and coating elements at the contact zone provided a clear indication of diffusion in active mode, showing a strong metallurgical bond across the interface.

Keywords:

Friction Surfacing, Al-Ni composite, Taguchi’s optimisation, Grain refinement, Diffusion.

References:

[1] Dillip Kumar Sahoo, P. Guna, and S. Deepan, “Performance Analysis on Deposition of Aluminium 6063 Over en8 Medium Carbon Steel by Friction Surfacing,” Materials Today: Proceedings, vol. 64, pp. 116-123, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[2] Gulmira Sh. Yar-Mukhamedova et al., “Advancements in Coating Methods and Properties of Titanium-Based Composite Coatings: A Review,” ES Materials and Manufacturing, vol. 28, pp. 1-16, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[3] Enhao Zhang et al., “Research Progress on Process Optimization of Thermal-Sprayed Iron-Based Amorphous Coatings,” Integrating Materials and Manufacturing Innovation, vol. 14, pp. 247-275, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[4] Ebrahim Seidi, and Scott F. Miller, “A Novel Approach to Friction Surfacing: Experimental Analysis of Deposition from Radial Surface of a Consumable Tool,” Coatings, vol. 10, no. 11, pp. 1-17, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[5] Seyedeh Marjan Bararpour, Hamed Jamshidi Aval, and Roohollah Jamaati, “Combined Experimental-Numerical Analysis of A356 Aluminum Alloy Friction Surfacing on AA2024 Aluminum Alloy Substrate,” Journal of Materials Research and Technology, vol. 25, pp. 4860-4875, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[6] R. George Sahaya Nixon, B.S. Mohanty, and R. Sathish, “Friction Surfacing of AISI 316 Over Mild Steel: A Characteriation Study,” Defence Technology, vol. 14, no. 4, pp. 306-312, 2018.
[CrossRef] [Google Scholar] [Publisher Link]
[7] Rajat Gupta, and Lalit Thakur, “A Study of Parametric Optimization, Microstructure and Wear Behavior of an AA7075–SiC Composite Coating Developed by Friction Surfacing,” Journal of Adhesion Science and Technology, vol. 38, no. 12, pp. 2166-2190, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[8] V. Fitseva, S. Hanke, and J. F. Dos Santos, “Influence of Rotational Speed on Process Characteristics in Friction Surfacing of Ti-6Al-4V,” Materials and Manufacturing Processes, vol. 32, no. 5, pp. 557-563, 2017.
[CrossRef] [Google Scholar] [Publisher Link]
[9] N.V. Chithra, “Effect of Reinforcement Addition on Mechanical Behavior of Al MMC - A Critical Review,” Journal of Environmental Nanotechnology, vol. 13, no. 2, pp. 65-79, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[10] S. Ganeshkumar, and S. Venkatesh, “Manufacturing Techniques and Applications of Multifunctional Metal Matrix Composites,” Functional Composite Materials: Manufacturing Technology and Experimental Application, pp. 157-167, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[11] M. Ravikumar et al., “Experimental Studies and Optimisation of Machining Performance Measurement for Al7075/n-SiCp Composite by using RSM and ANN Techniques,” Canadian Metallurgical Quarterly, pp. 1-14, 2025.
[CrossRef] [Google Scholar] [​​​​​​​Publisher Link]
[12] Pawel Jozwik, Wojciech Polkowski, and Zbigniew Bojar, “Applications of Ni3al Based Intermetallic Alloys—Current Stage and Potential Perceptivities,” Materials, vol. 8, no. 5, pp. 2537-2568, 2015.
[CrossRef] [​​​​​​​Google Scholar] [​​​​​​​Publisher Link]
[13] Liming Ke et al., “Al–Ni Intermetallic Composites Produced in Situ by Friction Stir Processing,” Journal of Alloys and Compounds, vol. 503, no. 2, pp. 494-499, 2010.
[CrossRef] [Google Scholar] [Publisher Link]
[14] J. Gandra, R.M. Miranda, and P. Vilaça, “Performance Analysis of Friction Surfacing,” Journal of Materials Processing Technology, vol. 212, no. 8, pp. 1676-1686, 2012.
[CrossRef] [Google Scholar] [Publisher Link]
[15] Ravi Butola et al., “Fabrication and Multi-objective Optimization of Friction Stir Processed Aluminium based Surface Composites using Taguchi Approach,” Surface Topography: Metrology and Properties, vol. 9, no. 2, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[16] Guangliang Zhang et al., “Laser Cladding Al/Ni Composite Coating and its Tribology Performance,” Surface Engineering, vol. 41, no. 2, pp. 266-278, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[17] Bodala Raja Sekhar et al., “Wear Characteristic of TiC Coated AISI 1020 Mild Steel Fabricated by TIG Cladding Method,” Materials Today: Proceedings, vol. 26, pp. 3288-3291, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[18] Peng Yu et al., “Formation of Al3Ni Nanofibers in an Al-Based Metal Matrix Composite Fabricated by Reaction Sintering,” Journal of Materials Research, vol. 19, no. 4, pp. 1187-1196, 2004.
[CrossRef] [Google Scholar] [Publisher Link]
[19] U. Ashok Kumar, Bharadwaj Kasi, and P. Laxminarayana, “Optimization of Friction Surfacing Process Parameters on Low Carbon Steel Using Taguchi Approach,” Materials Science Forum, vol. 969, pp. 691-696, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[20] Rajat Gupta, and Lalit Thakur, “Development of an AA 7075 Wear-Resistant Coating on AA 6082 via Friction Surfacing: Optimization and Characterization,” Journal of Materials Engineering and Performance, vol. 32, pp. 10311-10325, 2023. [CrossRef] [Google Scholar] [Publisher Link]
[21] Seyedeh Marjan Bararpour, Hamed Jamshidi Aval, and Roohollah Jamaati, “Modeling and Experimental Investigation on Friction Surfacing of Aluminum Alloys,” Journal of Alloys and Compounds, vol. 805, pp. 57-68, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[22] Ebrahim Seidi, and Scott F. Miller, “Lateral Friction Surfacing: Experimental and Metallurgical Analysis of Different Aluminum Alloy Depositions,” Journal of Materials Research and Technology, vol. 15, pp. 5948-5967, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[23] Parisa Pirhayati, and Hamed Jamshidi Aval, “An Investigation on Thermo-Mechanical and Microstructural Issues in Friction Surfacing of Al–Cu Aluminum Alloys,” Materials Research Express, vol. 6, no. 5, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[24] Márcio Levi Kramer de Macedo et al., “Deposit by Friction Surfacing and its Applications,” Welding International, vol. 24, no. 6, pp. 422-431, 2010.
[CrossRef] [Google Scholar] [Publisher Link]
[25] J. J. S. Dilip et al., “Use of Friction Surfacing for Additive Manufacturing,” Materials and Manufacturing Processes, vol. 28, no. 2, pp. 189-194, 2013.
[CrossRef] [Google Scholar] [Publisher Link]
[26] A.W. Batchelor et al., “The Effect of Metal Type and Multi-Layering on Friction Surfacing,” Journal of Materials Processing Technology, vol. 57, no. 1-2, pp. 172-181, 1996.
[CrossRef] [Google Scholar] [Publisher Link]
[27] Y. Aiman, S. Syahrullail, and M.K.A. Hamid, “Optimisation of Friction Surfacing Process Parameters for a1100 Aluminium Utilising Different Derivatives of Palm Oil based on Closed Forging Test,” Biomass Conversion and Biorefinery, vol. 14, pp. 8857-8874, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[28] Arne Roos et al., “Friction Surfacing of Aluminum to Steel: Influence of Different Substrate Surface Topographies,” Materials & Design, vol. 235, pp. 1-12, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[29] K. Sri Ram Vikas et al., “Influence of Heat Treatments on Microstructural and Mechanical Properties of Grade 5 Titanium Friction Welds,” Engineering Research Express, vol. 4, no. 2, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[30] J.C. Galvis et al., “Influence of Friction Surfacing Process Parameters to Deposit AA6351-T6 over AA5052-H32 using Conventional Milling Machine,” Journal of Materials Processing Technology, vol. 245, pp. 91-105, 2017.
[CrossRef] [Google Scholar] [Publisher Link]
[31] X.P. Tao et al., “Effect of Fe and Ni Contents on Microstructure and Wear Resistance of Aluminum Bronze Coatings on 316 Stainless Steel by Laser Cladding,” Surface and Coatings Technology, vol. 342, pp. 76-84, 2018.
[CrossRef] [Google Scholar] [Publisher Link]
[32] Lijia Zhao et al., “Effect of Particle Size on Ceramic Particle Content in Cold Sprayed Al-Based Metal Matrix Composite Coating,” Journal of Thermal Spray Technology, vol. 31, pp. 2505-2516, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[33] Ramezanali Farajollahi, Hamed Jamshidi Aval, and Roohollah Jamaati, “Effect of Friction Surfacing Parameters on the Microstructural, Mechanical Properties, and Wear Characteristic of Al-Cu-Mg Alloy Coating Reinforced by Nickel Aluminide,” Archives of Civil and Mechanical Engineering, vol. 22, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[34] P. Azhagarsamy, K. Sekar, and K. P. Murali, “Nickel Aluminide Intermetallic Composites Fabricated by Various Processing Routes – A Review,” Materials Science and Technology, vol. 38, no. 9, pp. 556-571, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[35] D. Prince Sahaya Sudherson et al., “Experimental Investigation on Corrosion Behavior of Friction Surfaced Mild Steel with Aluminum Alloy 5083-Cadmium Composite,” Materials Research Express, vol. 6, no. 8, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[36] Armi Tabaghi, Hossein Tavakoli, and Abdolvahed Kami, “Deposition of an Al/SiC Composite Coating on Steel by Friction Surfacing: Corrosion and Wear Properties,” Mechanics of Advanced Composite Structures, vol. 9, no. 2, pp. 287-296, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[37] K.H.S. Silva et al., “The Behaviour of AISI 4340 Steel Coatings on Low Carbon Steel Substrate Produced by Friction Surfacing,” Surface and Coatings Technology, vol. 399, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[38] Zina Kallien et al., “Application of Friction Surfacing for Solid State Additive Manufacturing of Cylindrical Shell Structures,” Additive Manufacturing Letters, vol. 8, pp. 1-8, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[39] Rajat Gupta, and Lalit Thakur, “Influence of Micro-Sized Al2O3 Particles on Mechanical and Wear Performance of an AA7075-Al2O3 Composite Coating Developed by Friction Surfacing,” International Journal on Interactive Design and Manufacturing, vol. 18, pp. 5583-5597, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[40] Nartu Mohan Sai Kiran Kumar Yadav et al., “Friction Surface Layer Deposition of Triple-phase Al10Cr12Fe35Mn23Ni20 High Entropy Alloy: Process Optimization and Microstructural Evolution,” Materials Science and Engineering: A, vol. 927, pp. 1-37, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[41] Noah E. El-Zathry et al., “Friction Stir-Based Techniques: An Overview,” Welding in the World, vol. 69, pp. 327-361, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[42] B. M. Karthik et al., “Effect of Weight of Reinforcement and Coating Thickness on the Hardness of Stir Cast AL7075–Nickel Coated Duralumin Powder MMC,” Journal of Applied Engineering Science, vol. 20, no. 3, pp. 900-907, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[43] Xun He, Xiao Peng, and Juan Fang, “Study on the Microstructure and High-Temperature Oxidation Performance of β-NiAl/γ′-Ni3Al Intermetallic Compounds Fabricated by Laser Metal Deposition,” Metals, vol. 13, no. 8, pp. 1-11, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[44] D. Guo et al., “Friction Surfacing of AISI 904L Super Austenitic Stainless Steel Coatings: Microstructure and Properties,” Surface and Coatings Technology, vol. 408, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[45] Aishwarya Deshpande et al., “Fully Consolidated Deposits From Oxide Dispersion Strengthened and Silicon Steel Powders Via Friction Surfacing,” Journal of Manufacturing Science and Engineering, vol. 146, no. 10, pp. 1-9, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[46] Marius Hoffmann, Arne Roos, and Benjamin Klusemann, “Friction Surfacing of Aluminum Alloys on Ti6Al4V - Investigation of Process Parameters, Material Deposition Behavior and Bonding Mechanisms,” Surface and Coatings Technology, vol. 503, pp. 1-12, 2025.
[CrossRef] [Google Scholar] [Publisher Link]