Our objective for this project is to achieve successful deposition of Stainless Steel 304L on the same material.
Based on previous studies, and considering force limitations of the HAAS Model TM-1 “Tool Room Mill” machine we were using, we decided to use rods of 12.72 mm diameter and approx 70 mm length. The first step was to develop a design of experiments. We worked with the following parameters:
Fixed parameters:
- Plunge depth
- Initial Dwell time
- Initial Plunge rate
- Traverse (deposition) length
Control Parameters:
- Rotational speed: 1000 to 4000 RPM
- Plunge rate (during travel): 30 to 50 mm/min
- Traverse rate: 30 to 90 mm/min (only for 4000 RPM, 50 mm/min plunge rate)
For the first round of experiments, we performed 27 tests (including failed experiments).
Parameters measured:
- Length and weight of the pre and post process consumable rods
- Height and width of the steady state depositions
Below is a video of what we believe to be one of the better tests from stage 1.
Video 1: The Good – Good deposition, bonded well to the base plate
Below is a video of what we believe to be one of the bad tests from stage 1.
Video 2: The Bad – Thick deposition, but not bonded to the base plate
Below is a video of what we believe to be one of the worst tests from stage 1.
Video 3: The Ugly – Rod loses contact with the base plate, no consistent deposition
Based on the parameters at which we got consistent, steady state depositions which were bonded to the base plate, we designed another matrix of experiments around these conditions.
New parameters used:
- Rotational Speed – 2000 to 4000 RPM
- Traverse feed rate – 60 mm/min to 120 mm/min
- Rod length – approx. 90mm
Each test was performed with an aluminium backing plate (under the base plate) and also a stainless steel backing plate.
Parameters Measured:
- Forces – in X, Y and Z directions
- Length and weight of the pre and post process consumable rods
- Height and width of the steady state depositions
We achieved better test results for this stage, and also huge variations for the same parameters when different backing plates were used.
Figure 1 shows the workpiece and base plate from one of the tests in stage 2.
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| (a) | (b) |
| Figure 1:Test 37 (a) Consumable rod (b) Base plate | |
Further steps:
- Analysis of force data for various deposition conditions
- Microstructure analysis of cut sections of the depositions and workpieces
- One deposition of the best condition over an area that has through-holes drilled into it.
References:
- Gandra, J., D. Pereira, R. M. Miranda and P. Vilaça. “Influence of process parameters in the friction surfacing.” Forty Sixth CIRP Conference on Manufacturing Systems 2013.
- Amit Kumar Singh, Madhusudan Reddy G, Srinivas Rao K. “Pitting corrosion resistance and bond strength of stainless steel overlay by friction surfacing on high strength low alloy steel.” Defense Technol 2015; 11:99-307.