Numerical and Experimental Investigation of Residual Stress and Bond Strength in Friction Surface Cladding Process

The bond strength is an essential property of cladded products, which are produced by deposition processes such as friction surface cladding (FSC). Friction and severe plastic deformation of the deposited material cause the process to take place at elevated temperatures, and inhomogeneous cooling after the deposition process can lead to the formation of residual stresses that influence the remaining bond strength. A novel simulation method for the evaluation of the residual stress distribution in clad layer and substrate after the cladding of AA6060 onto an AA2024 substrate is proposed in this study. The effect of residual stresses on the bond strength was correlated with data gathered from 3-point bending tests aimed at the determination of the mechanical properties at the clad layer–substrate interface. The results show that on the one side, the occurrence of a higher compressive residual stress magnitude increases the bond strength, but on the other side, this relationship is not always true for average tool temperature, tool rotating speed, normal force, and tool tilt angle. Therefore, it is necessary to investigate the effect of average tool temperature, tool rotating speed, normal force, and tool tilt angle parameters on the residual stress to find the best process window for carrying out the process to have optimal bond strength.