Surface Property Enhancement of Al–Si–Cu Alloy Coating by Fast Multiple Rotation Rolling

Herein, the effect of high rotational speed fast multiple rotations rolling (FMRR) on the microstructure, mechanical properties, and wear resistance of an Al–Si–Cu alloy coating friction surfaced on AA1050 aluminum alloy is investigated. The FMRR process is performed at a rotational speed of 3000 rpm with traverse speeds of 50, 80, 110, and 140 mm min −1 . The microstructure, mechanical properties, and wear resistance are examined by optical microscope, scanning electron microscope, electron backscatter diffraction, transmission electron microscope, nanoindentation test, microhardness test, and pin‐on‐disc wear test. The results show that as the traverse speed increases from 50 to 140 mm min −1 , surface roughness decreases from 6.3 ± 0.3 to 3.2 ± 0.2 μm. Additionally, with the increase in traverse speed, the coating height increases from 3.8 ± 0.3 to 4.7 ± 0.4 mm, while the coating width decreases from 37.1 ± 1.1 to 25.4 ± 1.3 mm. Furthermore, as the traverse speed increases from 50 to 140 mm min −1 , the average hardness of the FMRR‐processed layer increases from 5.6 ± 0.6 to 10.2 ± 0.6 GPa. At a traverse speed of 140 mm min −1 , the wear resistance of the FMRR‐processed layer increases by 20% compared to the Al–Si–Cu alloy consumable rod.