The effect of process parameters on the residual stress in friction surface cladding

Friction surface cladding (FSC) is a newly developed solid-state cladding process. The effect of the process parameters on the residual stress is one of the aspects of this new process which has very high potential for research. The present study has been carried out to investigate the effect of three parameters; h₀: predefined height from the substrate, Ω: tool rotation velocity and V_f: the clad material supply feed rate on the residual stress. A design of experiments method was used to select the parameter values in a validated process simulation model. The results showed that the effects of the three parameters are interrelated. Both Ω and h₀ have a linear effect on the residual stress value and changing the V_f, changes the slope of this linear effect. V_f itself may have linear or nonlinear effect on the residual stress. It is found that for some values of V_f, variation of Ω and h₀ does not affect the residual stress. An optimized set of the three parameters is also suggested.