Effect of overlapping deposition strategy on microstructure and mechanical properties of Al-clad steel by AFSD

Cladding of the aluminum (Al) layer on steel was successfully implemented via additive friction stir deposition (AFSD). We revealed the relationship between the overlapping deposition strategy of AFSD and the resultant microstructure and mechanical properties of Al-clad steel for the first time. Overlapping deposition strategies efficiently improved the adhesion of the Al layer on steel in the boundary region owing to the sufficient material flow and large plastic deformation. This is in contrast to the sample without overlapping where the Al/steel interface in the boundary region is characterized by holes and weak bonding. In particular, the maximum shear strength (109.0 MPa) was obtained for the sample with an overlap of 8 mm, even higher than that of the single-pass sample. This study provided a novel approach to the fabrication of large-scaled clad layers on hard substrates, and this strategy is expected to greatly contribute to the adoption of AFSD in the fields of cladding, joining, and coating.