Abstract

This proposal will study lateral friction surfacing, an innovative solid-state metal deposition technique, for localized repair of pipelines, vessels, and storage tanks. Unlike conventional friction surfacing, which uses the end face of a rotating consumable tool, lateral friction surfacing employs the radial surface to achieve material transfer at lower process temperatures, producing thinner, smoother, and more uniform coatings with minimal thermal impact. This approach mitigates issues such as fusion, dilution, and residual stresses common in fusion-based methods. The research seeks to deepen the understanding of this technique by investigating key process parameters, such as force, rotational speed, and traverse speed, and their influence on coating quality, microstructural evolution, and mechanical performance. By developing a custom lateral friction surfacing system equipped with real-time force monitoring, infrared thermography, and advanced characterization techniques (SEM, EDS, and TEM), the study will optimize deposition strategies for durable and corrosion-resistant coatings on industrially relevant substrates like carbon and stainless steel. This includes evaluating multi-pass deposition strategies to achieve functionally graded coatings and assessing material combinations such as aluminum, zinc, and steel alloys for enhanced wear and corrosion resistance. The project will establish laboratory infrastructure, train graduate students, and prototype applications for pipeline repair, positioning lateral friction surfacing as a scalable, cost-effective solution for extending the service life of critical infrastructure. By addressing equipment limitations and demonstrating real-world feasibility, the research aims to bridge the gap between laboratory innovation and industrial adoption, advancing sustainable localized repair technologies.

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