Browsing by Author "Mulik R.S."

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An assessment for mechanical and microstructure behavior of dissimilar material welded joint between nuclear grade martensitic P91 and austenitic SS304 L steel
(2019) Thakare J.G.; Pandey C.; Mahapatra M.M.; Mulik R.S.
The microstructural evolution and mechanical properties of gas tungsten arc welded creep strength enhanced martensitic (CSEM) and austenitic stainless steel (SS) dissimilar welded joint is explored in the as welded (AW) and post weld heat treated (PWHT) conditions. The as received normalized and tempered P91 steel has been welded with SS304 L by preparing a conventional groove and employing a P91 GTAW filler wire. The welded plate is subjected to PWHT at 760 �C for 120 min followed by air cooling. The P91 steel in as received condition exhibited fully martensitic (tempered) structure with lathe morphology and prior austenite grain boundaries while SS304 L have austenitic structure with twins. The heterogeneity (as-welded condition) across the welded joint were produced in terms of microstructure and mechanical properties (hardness, Charpy toughness and tensile strength). The variation in mechanical properties has been minimized after the PWHT. PWHT has observed a drastic influence on mechanical properties and microstructure of weld fusion zone and HAZ of P91 side however, remain unaffected for the SS304 L side HAZ. The strength of the welded joint have been measured 1016 � 2.5 MPa and 906 � 6.5 in as-welded and PWHT condition with joint efficiency of 140 % and 125 %, respectively. � 2019 The Society of Manufacturing Engineers
Characterization of P92 Steel weldments in as-welded and PWHT conditions: Room-temperature tensile tests and microhardness measurements led to improving the ductility of the weld joints
(2018) Saini N.; Pandey C.; Mahapatra M.M.; Mulik R.S.
P92 steels have been developed as a candidate material for power plant components that operate in a temperature range of 620o-650�C. A heterogeneous microstructure formation across the P92 weldments makes the wettability of P92 steel a serious issue. The other problem that arises in P92 steel weldments is the formation of ?-ferrite due to the presence of a higher weight percentage of ferrite stabilizers such as V and Nb. as well as W and Mo. In the present work, the shielded metal arc welding (SMAW) process was utilized to prepare the P92 steel weld joints. After welding, postweld heat treatment (PWHT) was performed at 760�C for 2 h. To characterize the weld joints, room-temperature tensile tests and microhardness measurements were performed in the as-welded and PWHT conditions. The subsequent PWHT resulted in a decrease in the hardness gradient across the weldments. The PWHT resulted in enhancing the : ductility of the weld joints. � 2018 American Welding Society. All rights reserved.
A comparative study of ductile-brittle transition behavior and fractography of P91 and P92 steel
(2017) Saini N.; Pandey C.; Mahapatra M.M.; Narang H.K.; Mulik R.S.; Kumar P.
The modified 9Cr-1Mo (P91) and 9Cr- 0.5Mo- 1.8W (P92) steel used in fast breeder reactor is exposed to irradiation during service which severely affects the dynamic fracture resistance by increasing the ductile to brittle transition temperature (DBTT). Thus, even at room temperature, the steel can become brittle and prone to cracking. In the present investigation, to elucidate the influence of low temperature on the DBTT, Charpy toughness test was performed on creep strength enhanced ferritic P91 and P92 steel. Lower DBTT was observed for the P92 steel as compared to P91 steel. To find the mode of fracture, the fractured Charpy toughness specimens were investigated using a field electron scanning electron microscope (FESEM). The fracture surface revealed the brittle mode of fracture at a lower temperature for both the steels while the mixed mode of fracture was noticed at room temperature and above. � 2017 Elsevier Ltd
Design, development, and calibration of octagonal ring type dynamometer with FEA for measurement of drilling thrust and Torque
(2020) Gaikwad S.V.; Mahapatra M.M.; Mulik R.S.
In this study, the design, development, and calibration of a strain-gauge-based octagonal ring type tool dynamometer was carried out. This dynamometer has the capacity to simultaneously measure thrust and torque during drilling operation. The thin strain ring theory was used for finalizing the dimensions of strain rings. Finite element analysis was carried out to compare theoretical strains with the experimental values and to finalize the location of strain gauges. The thrust force and torque were measured by eight strain gauges, each forming a Wheatstone bridge circuit, converting the deflections of elastic strain rings to proportional electrical signals. A suitable data acquisition system was used for recording the thrust and torque in a computer system. Calibration curves were plotted by applying known thrust and torque repeatedly. It was observed that the designed tool dynamometer is capable of measuring the cutting forces satisfactorily. � 2018 by ASTM International.
Effect of carbon nanotubes and aluminum oxide on the properties of a plasma sprayed thermal barrier coating
(2018) Thakare J.G.; Mulik R.S.; Mahapatra M.M.
To protect the structural components of a power generating unit from the corrosive environment, thermal spray coatings are applied to the components. In the present work, four different types of thermal barrier coating (TBC) viz. partially stabilised zirconia (8YSZ), zirconia-20% alumina (ZA) composite coating without carbon nanotube (CNT) reinforcement, and ZA with 1% and 3% CNT reinforcement. The coating was deposited on NiCrAlY coated P91 steel using a plasma spraying process. The coating microstructure and phases were characterised using field emission scanning electron microscope (FE-SEM) with energy dispersive spectroscopy (EDS). The phases of the coating were analyzed using X-ray diffraction technique. The effect of CNT reinforcement on the thermal conductivity, porosity, and hardness of the composite coatings was investigated. The protective behavior of the coatings was characterised by potentiodynamic polarization testing and electrochemical impedance measurements. The thermal conductivity of the composite coating was found to be increased with increasing CNT content. Hardness was found to be highest for 3% CNT reinforcement and the thermal conductivity was found to increase with decreasing porosity. The electrochemical measurements indicate that reinforcement of CNT in zirconia alumina composite coating improved its corrosion resistance. � 2017 Elsevier Ltd and Techna Group S.r.l.
Effect of grit blasting and thermal spraying on microstructure evolution of P91 weldment
(2018) Thakare J.G.; Pandey C.; Mulik R.S.; Mahapatra M.M.; Narang H.K.
In the present work, studies have been carried out on the variations in the microstructure and hardness of P91 base-metal and welded joint. This variations result from the grit blasting and thermal cycle experienced during the thermal spraying process. The microstructural effects have been analyzed in terms of the depth of the deformation zone. Scanning Electron Microscopy and X-ray diffraction were used as characterization techniques. The grit blasting carried out prior to thermal spraying has resulted in the highest change in sub-surface hardness of the heat affected zone (HAZ). However, flame treatment further reduced the subsurface hardness of the heat affected zone. The depth of deformation zone was highest for inter-critical heat affected zone (IC-HAZ). The overall coating process resulted in an increase in subsurface hardness of various regions of HAZ and fusion zone (FZ). The base metal showed a 7% increase in subsurface hardness due to the overall coating process. The IC-HAZ showed maximum variation with 36% increase in subsurface hardness. The coarse grained heat affected zone (CG-HAZ) and FZ did not show any change in subsurface hardness. As a whole, the hardness and microstructure of the welded joint was observed to be more sensitive to the thermal spray coating process as compared to the base metal. � 2018 Polish Academy of Sciences. All Rights Reserved.
Effect of welding process and PWHT on ?-ferrite evolution in dissimilar P91 and P92 steel joint
(2018) Pandey C.; Mohan Mahapatra M.; Kumar P.; Mulik R.S.; Saini N.; Gopal Thakre J.
Ferritic/martensitic 9Cr-1Mo-V-Nb (P91) and 9Cr-0.5Mo-1.8W-V-Nb (P92) steel are used for high temperature (600-650�C) operating components in nuclear and thermal power plants. The present research work deals with the dissimilar joining of P91 and P92 steel using autogenous tungsten inert gas (TIG) welding and multi-pass gas tungsten arc welding (GTAW) with filler. The evolution of ?-ferrite patches in weld fusion zone and heat affected zones (HAZs) were characterized in as-welded and post weld heat treatment (PWHT) condition. PWHT was carried out at 760�C for 2 h and 6 h, for both autogenous-TIG and GTA weld joints. Charpy toughness and microhardness tests were performed for autogenous-TIG welding and GTA welding process under as-welded and PWHT condition. � 2018 Elsevier Ltd.
Estimation of strength and wear properties of Mg/SiC nanocomposite fabricated through FSP route
(2017) Deepan M.; Pandey C.; Saini N.; Mahapatra M.M.; Mulik R.S.
The present paper discusses the effects of friction stir processing (FSP) on properties of Mg�SiC nanocomposite. The magnesium-based RZ5 alloy, widely used for aerospace applications, was used in the present investigation as the matrix for the purpose of nanocomposite fabrication. SiC powders of nanosize were reinforced into the RZ5 matrix by FSP with varying process parameters. The process was studied with respect to the effects of parameters such as rotational speed, traverse rate, and number of passes on the nanocomposite. With appropriate parameters, uniform distribution of nanoSiC reinforcements was accomplished in the metal matrix. The abrasive wear property of the Mg�SiC nanocomposite was verified with respect to the FSP process parameters. A mathematical model was also developed to predict the strength and abrasive wear characteristics of the nanocomposite with respect to the FSP parameters. � 2017, The Brazilian Society of Mechanical Sciences and Engineering.
Evolution of nano-size precipitates during tempering of 9Cr-1Mo-1W-V-Nb steel and their influence on mechanical properties
(2018) Saini N.; Pandey C.; Mahapatra M.M.; Mulik R.S.
The aim of the characterization of P911 steel is to determine the consequence of different tempering temperature on nano-size particle evolution and their effect on the mechanical properties. P911 steel was normalized at 1040 �C for 1 h and subjected to varying tempering condition in the range of 720�800 �C for 2 h of tempering time. To study the effect of tempering temperature on nano-size particles distribution and grain size of P911 steel, field-emission scanning electron microscope (FESEM) and optical microscope (OM) were utilized. The other tests were hardness measurement and room-temperature tensile testing was performed to characterize the P911 steel for different tempering condition. The ultimate tensile strength (UTS) and hardness have found a great dependency on the area fraction of precipitates present in the microstructure. The UTS and hardness were observed to be increased continuously with increase in tempering temperature in range of 720�800 �C. � 2017 Elsevier B.V.
Hot corrosion behavior of plasma sprayed 8YSZ-alumina- CNT composite coating in Na2SO4�60% V2O5 molten salt environment
(2018) Thakare J.G.; Mulik R.S.; Mahapatra M.M.; upadhyaya R.
Hot corrosion (HC) behavior of air plasma sprayed 8% yttria stabilized zirconia (8YSZ) -alumina (YA) composite thermal barrier coating has been evaluated in the present work. Three variants of YA coatings were produced, two by reinforcing 1%, 3% multiwall carbon nanotube (MCNT) and one coating was obtained without any MCNT reinforcement. The creep strength enhanced ferritic P91 steel was used as substrate material for coating. Na2SO4 and V2O5 salts mixed in 2:3 ratio was applied to the coating and subjected to 800 �C for 120 h in an electric furnace. The microstructure and phase characterization of the coating was carried out before and after HC using scanning electron microscope (SEM) and X-ray diffraction (XRD) respectively. Energy dispersive spectroscopy (EDS) integrated with the SEM was used for elemental analysis of the coating. The investigation reveals improved isothermal HC behavior of 1% MCNT reinforced coating. The dominating effect of the HC was recognized as depletion of yttria leading to destabilization of 8YSZ. The formation of YVO4 was the corrosion product containing the depleted Y2O3 of YSZ. The 1% and 3% MCNT reinforced coating exhibited monoclinic phase percentage of around 9% and 34% respectively. Nanoindentation was carried out along the cross-section before and after the isothermal HC. The Youngs modulus after HC increased by 46%, 42%, 12.5% and 38% for 8Y, 8YA, 8YA1C and 8YA3C coating, respectively. Weibull modulus of Youngs modulus of bond coats was used to identify the efficiency of top coat in retarding the infiltration of molten salt. The bond coat of 8YA1C coating exhibited lowest modulus value (m = 8.55) indicated non-uniform infiltration of detrimental species. The 1% MCNT reinforced thermal barrier coating (TBC) system was more resistant to degradation than the conventional 8YSZ and YA composite coatings. � 2018 Elsevier Ltd and Techna Group S.r.l.
Influence of filler metals and PWHT regime on the microstructure and mechanical property relationships of CSEF steels dissimilar welded joints
(2019) Saini N.; Mulik R.S.; Mahapatra M.M.
The nuclear grade modified 9Cr�1Mo (P91) and 9Cr-0.5Mo-1.8W�V�Nb (P92) are commonly used material for power plant components operating in the temperature range of 600�650 �C. For such steels, the creep strength at the elevated operating temperature is the prime criteria. However, microstructure stability and notch toughness also play an important role, especially for the welded joints to meet the pressure test at room temperature. The room temperature mechanical properties of the welded joint are strongly influenced by the welding process, filler composition, composition of the base plate and heat treatment performed after the welding. In present work, P91 and P92 dissimilar multi-pass welded joints have been produced using the different filler rod. The microstructure of the welded joint has been studied for the different filler composition in various heat treatment condition. The room temperature Charpy impact toughness and tensile properties for the different welded joints (different filler) have been also studied and related with the microstructure of the welded joint. From the results, it has been concluded that a higher amount of ferrite stabilizer in P92 filler promotes the formation of the ? ferrite in the weld fusion zone. � 2019 Elsevier Ltd
An investigation into fabrication and characterization of direct reaction synthesized Al-7079-TiC in situ metal matrix composites
(2019) Sujith S.V.; Mahapatra M.M.; Mulik R.S.
The present study was attempted to highlight a novel direct reaction synthesis in which traditional casting plus rapid solidification techniques were implemented to produce Al-7079-TiC in situ composites with homogenous microstructure and improved dispersion strengthening by the reinforcing phases. Casted samples were effectively characterized by scanning electron microscopy followed by energy dispersive spectroscopy and X-ray diffraction. Ingot metallurgy showed a homogenous distribution of TiC particles inside the grain. This particle behavior acted as an excellent nucleation sites for the Al dendrites to grow unvaryingly. TiC reinforcements have semi coherent relationship with ?-Al matrix. It was observed that eutectic boundary includes the second phases based on ? (MgZn2) and Mg(Zn, Cu, Al)2. Almost 90% of the in situ reinforced TiC were homogenously distributed along the center of the grain. Thermal history conditions have shown an exothermic behavior during casting. Experimental results revealed the evolution of TiC particles in super-heated melt region, i.e. dissolution of titanium continued by reaction of titanium with diffused carbon in the Al matrix to form TiC particles. Further they acted as nucleation sites for the ?-Al dendrites to grow homogenously. This study presents optimum process temperature for the Al-TiC in situ synthesis. � 2018 Politechnika Wroc?awska
Mechanical property evaluation of carbon nanotubes reinforced plasma sprayed YSZ-alumina composite coating
(2018) Thakare J.G.; Pandey C.; Mulik R.S.; Mahapatra M.M.
Yttria (8%) stabilized zirconia (8YSZ)-alumina-carbon nanotube (CNT) composite coatings were deposited using air plasma spray (APS) technique. Three zirconia alumina (ZA) composite coatings, without CNT reinforcement, and with 1%CNT, 3%CNT reinforcement were deposited using identical process parameters (500 A and 66 V). Indentation method was used to characterize mechanical behavior of coatings. The CNT reinforced composite coating showed superior mechanical properties as compared to the conventional 8YSZ coating. The addition of alumina and 1%CNTs increased the Young's modulus by around 25% and 40%, respectively. However, the increase in CNT content decreased the Young's modulus as a result of CNT agglomeration. The hardness, fracture toughness increased with addition of alumina and CNT. The fracture toughness increased from 0.55 � 0.26 MPa m1/2 for 8YSZ to 1.76 � 0.65 MPa m1/2 for 17%alumina-3%CNT reinforcement due to various toughening mechanisms like crack deflection, bridging etc. The maximum displacement of indenter was found to decrease from ~ 176 nm for conventional YSZ coating to ~ 120 nm for 3% CNT reinforced coating. The surface roughness (Ra) was found to be decrease with alumina addition and CNT reinforced coating. The CNT reinforced coating showed surface roughness of around 6 �m. Scanning electron microscopy (SEM) with energy dispersive spectroscopy (EDS) was used to characterize the coating microstructure and elemental composition respectively. � 2018 Elsevier Ltd and Techna Group S.r.l.
Microstructural characterization and experimental investigations into two body abrasive wear behavior of Al-7079/TiC in-situ metal matrix composites
(2019) SV S.; Mahapatra M.M.; Mulik R.S.
High strength Al-7079 aluminum metal-matrix composites with 5, 7 and 9 wt.% of TiC particulate reinforcement were procured by in-situ melt reaction method. Scanning electron microscopy (SEM) and XRD analysis were conducted in order to confirm the presence of titanium carbide (TiC) particles and homogeneity inside the aluminum matrix. The parameters like applied load (9.8�29.4 N), sliding distance (1000�2000 m), sliding velocity (1.5 m/s) and SiC-P-600 grit paper (25 �m) were used in this study. The influence of sliding distance, applied load and wt.% of (TiC) reinforcement on in-situ Al-7079 under two body abrasion was investigated. Further, the obtained results were compared with the base Al-7079 alloy. It was examined that, the in-situ reinforced composites exhibited significantly greater wear resistance of 20�60% compared to conventional as cast Al-7079 base matrix. Experimental results confirmed that the wt.% of TiC and sliding distance had higher influence on coefficient of friction and the weight loss was highly affected by the applied load. Further the wear mechanisms involved in the worn surfaces were demonstrated through atomic force microscopy and SEM analysis throughout the surfaces. � IMechE 2019.
Microstructural Evolution and Mechanical Properties of CSEF/M P92 Steel Weldments Welded Using Different Filler Compositions
(2018) Saini N.; Mahapatra M.M.; Mulik R.S.
In the present investigation, P92 steel weld joints were prepared using a shielded metal arc welding (SMAW) process for two different fillers, E911 and P92. A comparative study was performed on the microstructural evolution, tensile strength, microhardness, and Charpy toughness across the P92 steel weldments in the as-welded and post-weld heat-treated (PWHT) conditions. The PWHT was performed at 760��C for 2�hours. To study the effect of the different filler metals and PWHT on the mechanical properties, longitudinal and transverse tensile tests were carried out at room temperature for a constant cross-head speed of 1 mm/min. In the longitudinal direction, the tensile strength of the P92 steel welds was measured as 958��35 and 1359��38�MPa for the E911 and P92 filler, respectively. In the as-welded condition, the transverse tensile specimens were fractured from the fine-grained heat-affected zone or inter-critical heat-affected zone (FGHAZ/ICHAZ) and, after PWHT, the fracture location was shifted to over-tempered base metal from the FGHAZ/ICHAZ. After the PWHT, the tempering reaction resulted in lowering of the hardness throughout the weldment. After PWHT, the Charpy toughness of the weld fusion zone and heat-affected zone (HAZ) of the E911 filler weldments was measured as 66��5 and 142��8�J, respectively. The minimum required Charpy toughness of 47�J (EN1557: 1997) was achieved after the PWHT for both E911 and P92 filler. � 2018, The Minerals, Metals & Materials Society and ASM International.
Microstructure and mechanical properties of D-Gun sprayed Cr3C2-NiCr coating on P91 steel subjected to long term thermal exposure at 650 �c
(2019) Thakare J.G.; Pandey C.; Mulik R.S.; Mahapatra M.M.
Thermally sprayed 75Cr3C2-25NiCr coating is applied on structural components to improve corrosion, oxidation and erosion behaviour at high temperature. In order to understand the microstructural and mechanical behaviour of coating a long term investigation was carried out at 650 �C. The Objective of the present work is to study the effect of long term heat treatment (i.e. 650 �C/ 3000 h) on various characteristics of the detonation gun sprayed 75Cr3C2-25NiCr coating. Hardness and nanoindentation studies were carried out on Cr3C2-NiCr coating after fixed time intervals. The morphological and microstructural features of the coated surface were characterized using scanning electron microscope (SEM). The phases formed during the long term exposure were identified by x-ray diffraction (XRD) technique. The coating showed the presence of various Cr, Ni, based oxides, Fe and Ni based spinels. Vanadium, niobium, and molybdenum showed maximum tendency to diffusion from substrate to the coating. Hardness of the coating reached a maximum value of 870 HV after 2160 h of exposure. The hardness of coating observed an initial drop in hardness due to carbide coarsening which was recovered by precipitation of carbides from the solid solution. � 2019 IOP Publishing Ltd.
A New Hot Tearing Assessment by Using Stepped Ring Core Mold and the Effect of Strontium on the Hot-Tearing Resistance of Al�6�wt% Zn Based Alloy
(2018) Sujith S.V.; Mahapatra M.M.; Mulik R.S.
Automobile and aerospace industries use thin wall aluminium alloy castings which provide lighter structures with excellent mechanical properties. Production of thin wall castings is more challenging due to hot tear formation. Lack of fluidity in molten alloy causes hot tears and must be addressed in thin wall castings of Al-alloys. The present study is focused on a new technique known as stepped ring mould casting. It is possible to assess the hot tear susceptibility of Al�6Zn alloys by varying ring thickness to find out the critical thickness for occurrence of hot tears. The alloy was cast using different strontium (Sr) concentrations (0.2, 0.4, 0.6%). Effects of strontium concentrations were studied in terms of fluidity, porosity content, microstructure and tensile properties of Al�6Zn alloy. In the present work, unmodified and Sr modified alloy casts were characterized by SEM, EDS and XRD respectively. Al�6Zn ingots were procured by master alloy route. Repetition of stepped ring test on the critical thickness showed that hot tear were successfully eliminated significantly due to the addition of Sr. On the other hand, 0.6% Sr also exhibited a good amount of porosity and decrease in elongation. Shorter fluidity length was observed in 0.2% Sr modified alloy. Mechanical and metallographic tests revealed that the alloy castings modified with 0.4% Sr offered better results in yield strength, less porosity and an improved hot tear resistance at micro and macro levels. � 2017, The Indian Institute of Metals - IIM.
On study of effect of varying tempering temperature and notch geometry on fracture surface morphology of P911 (9Cr-1Mo-1W-V-Nb) steel
(2018) Saini N.; Pandey C.; Mahapatra M.M.; Mulik R.S.
Before putting in service, the creep strength enhanced ferritic (CSEF) steels are subjected to varying tempering treatment to produce a vast array of mechanical properties and to achieve the optimum combination of microstructure and mechanical properties by controlling normalizing and tempering temperature/time. In the present investigation, P911 steel was subjected to a fixed normalizing temperature of 1040 �C for 1 h and then, subjected to varying tempering temperature (720 �C�800 �C) for 2 h of tempering time. The effect of notch geometry on the tensile properties with respect to the varying tempering temperature was also investigated. The microstructural characterization was studied using optical microscope and field-emission scanning electron microscope (FESEM). A decrease in grain size, hardness and strength were noticed with increase in tempering temperature initially but after 740 �C, the grain size and strength were found to be increased continuously. The area fraction of precipitates was found to be varied inversely with the grain size. For a particular tempering temperature, an increase in notch depth resulted in increase in strength and decrease in ductility. The best combination of hardness, ductility and strength were achieved after normalized at 1040 �C for 1 h and tempered at 760 �C for 2 h. � 2017 Elsevier Ltd
Prior-austenite grain refinement in P92 steel using double austenitization treatment
(2019) Saini N.; Mulik R.S.; Mahapatra M.M.
The experimental investigation of 'double austenitization based normalizing and tempering' (DNT) heat treatments on tensile behavior and microstructural morphology of the CSEF/M P92 steel was carried out and compared it with the 'conventional normalizing and tempering' (CNT) heat treatment. The CNT treatment was performed at the normalizing temperature of 1040 �C for 60 min, followed by air cooling and then tempered at 760 �C for 120 min, followed by the air cooling. The DNT treatment involved the initial austenitizing at the temperature 950, 1100 and 1150 �C for 60 min, followed by the water quenching for higher dislocation density and then further austenitized at 1040 �C for 60 min followed by the air cooling. After the double austenitization based normalizing, tempering was performed at 760 �C for 2 h. The double austenitized samples are named as DNT 1 (950 �C), DNT 2 (1100 �C) and DNT 3 (1150 �C). The fine grain structure was obtained for the DNT 3 treatment. The fracture surface morphology of tensile tested specimen was studied using the field emission scanning electron microscope (FESEM). The results of tensile tests were obtained superior for the DNT treatment as compared to CNT treatment. Microstructure also showed the refinement of the grain size and lath width after the DNT treatment. � 2018 IOP Publishing Ltd.
Study on Effect of Process Variables on Distributed Compositional Characteristics in Metallurgically and Mechanically Bonded Claddings
(2017) Yadav R.; Pandey C.; Mahapatra M.M.; Mulik R.S.
In surface modification applications, cermets such as Cr3C2�NiCr are used to enhance the wear resistance of the substrate. Friction surfaced cladding is a recently developed solid-state surface modification process in which the deposition of the clad layer is accomplished below it�s melting temperature, so that degradation of the substrate is minimized. The present investigation discusses the friction surfaced cladding of Cr3C2�NiCr using consumable die steel rod. It was observed from the micrographs, that with the suitable combination of tool plunging rate (plunging speed), tool rotational speed and traverse rate, successful cladding of Cr3C2�NiCr was achieved. A plan of full factorial experiment was followed for determining the process variables for the successful deposition of Cr3C2�NiCr clad layer with the substrate. A mathematical model was developed to predict the composite clad dimensions and microhardness with respect to the process variables. Depending upon the process parameter, it was observed that the hardness of the clad and clad geometrical feature varied. The microstructural analysis exhibited sound and uniform bonding of clad layer to the substrate and near uniform distribution of Cr3C2�NiCr. Desirability based multi-response optimization procedure was followed to arrive at optimized Cr3C2�NiCr clad. � 2016, The Indian Institute of Metals - IIM.