The impact of traverse speed on the microstructure, mechanical properties, and wear resistance of Al-16Si alloy friction-surfaced on AA1050 alloy was evaluated using smoothed-particle hydrodynamics (SPH) simulation and experimental techniques. Results revealed a 54% and 20% decrease in the height and width of the coating, respectively, as traverse speed increased from 75 to 115 mm/min. Moreover, a corresponding increase in the unbonded zone at the interface was observed. Simulation results showed the maximum shear stress at the coating/substrate interface for samples coated at traverse speeds of 75, 95, and 115 mm/min to be 83, 95, and 112 MPa, respectively. As traverse speed escalated from 75 to 115 mm/min, the predicted torque and vertical force required for friction surfacing increased by 92% and 22%, respectively. The surface roughness declined while interface roughness increased by 49% and 86%, respectively, upon raising the traverse speed from 75 to 115 mm/min. An increase in the traverse speed from 75 to 95 mm/min resulted in a 11% grain size reduction and 13%, 12%, and 8% increases in hardness, strength, and wear resistance, respectively, when compared to the AA1050 substrate.
