International Journals of Advanced Research in

Computer Science and Software Engineering Research Article April

ISSN: 2277-128X (Volume-8, Issue-4) a 2018

Special Issue: National Conference on Emerging Trends in Engineering 2018

Conference Held at Sri Venkatesa Perumal College of Engineering & Technology, Puttur, A.P., India

Effects of Friction Welding Parameters on the Mechanical

Properties of Dissimilar Steel Joints
1
Sangathoti Haribabu, 2Muralimohan Cheepu* and 3T. Ramachandraiah
 Department of Mechanical Engineering, Sri Venkatesa Perumal College of Engineering and Technology Puttur
1

517583, Andhra Pradesh, India (e-mail: haribab204513@gmail.com)

2
Department of Mechatronics Engineering, Kyungsung University, Busan 48434, Republic of Korea
*Corresponding author (e-mail: muralicheepu@gmail.com)
3
Department of Mechanical Engineering, Sri Venkatesa Perumal College of Engineering and Technology Puttur 517583,
Andhra Pradesh, India (e-mail: chandramech05@gmail.com)

Abstract— In the present study, an influence of friction welding parameters on the mechanical properties of
dissimilar steel materials of AISI D3 tool steel and AISI 304 stainless steel joints. The welding conditions were
optimized with the effect of various welding parameters to find the optimal parameters for sound welds. The effects of
optimized welding parameters on the tensile strength of the joints were evaluated by plotting contour graphs. Among
the welding conditions, the combination of upset pressure and friction time exhibits a progressive effect on tensile
strength. As friction pressure and friction time increase, the joints tensile strength also gradually increases. The
maximum joint strength of the friction-welded dissimilar steel joints was 82 % of that of D2 tool steel. The
microstructures and hardness of the welded joints have been characterized and presented in this study. Additionally,
the interface characteristics were studied to identify the failure of the joints using energy-dispersive spectroscopy
analysis.

Key words—Friction welding, Optimization, Welding parameters, Mechanical properties and Microstructure.

I. INTRODUCTION
In the recent years, the joining of dissimilar materials gained more importance in various manufacturing industries. Most
importantly, the present manufacturing industries are concentrating on the cost effective materials and easy
manufacturing procedures [1-3]. The use of cost effective methods are most challenged than thee quality safety concerns
[4-7]. The dissimilar materials joining have several challenges unlike similar materials welding, which are prone to
failure during in service of its application. The most frequently noticeable structural failures of welded members are the
formation of solidification racks which are due to the improper selection of filler materials in conventional arc welding
methods [8-10]. The formation of secondary brittle phases commonly occurred for dissimilar materials joining using
conventional arc welding processes [11-14]. Additionally the formation of soft zone in the welds which is called as heat
affected zone has much importance in the dissimilar materials joints. The dissimilar joining of fusion welding methods
are ensued in the formation of very hard intermetallic compounds, which are detrimental to the formation of
metallurgical imperfections in the weld interface [15-18]. In order to overcome these issues solid state welding methods
have been implemented for dissimilar combination materials. Solid state welding methods retains the absence of melting
of substrates during welding and decreased the width of weld fusion zones. There are different solid state welding
methods are developed for dissimilar joining such as friction welding, friction stir welding, diffusion bonding, explosive
welding and roll bonding. Among these welding processes each and every one has its own applications and benefits
based on the fabrication of joint designs. Therefore, friction welding process has many advantages and various
applications especially for the joining of dissimilar materials [8, 19-22]. It is very comfortable and positive results
obtained using friction welding methods for applied to many dissimilar combination materials and are successfully
welded. The combination of dissimilar materials such as stainless steel to titanium, stainless steel to aluminum, ceramic
materials to aluminum are not reasonable to fabricate by applying conventional fusion welding processes. However,
friction welding method was overcome these issues and successfully applicable for dissimilar and similar combinations
of the joints with excellent joint properties [14, 23-27]. In addition, to improve the mechanical properties and strength of
dissimilar material combinations, interlayer material techniques has been executed to maintain the indirect contact
between the two dissimilar surfaces [28-31].
Furthermore, friction welding process was considered as low heat input process in the joint interface which is produced
by transformation of rotating mechanical energy into heat energy at the weld center. Thus the frictional rotation under the
external pressure on the substrates caused required heat input to the joint formation [32, 33]. In present industrial
applications, friction welding process become one of the major process for easy and fast welding, and is widely using for
joining of various materials and shapes such as plates to plates, rod to rod and rod to plates. Due to the increasing in
structural member for various industrial constructions and energy carrying products, austenitic stainless steels (ASS)

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 Haribabu et al., International Journal of Advanced Research in Computer Science and Software Engineering 8(4)
ISSN(E): 2277-128X, ISBN: 978-93-87396-07-4, pp. 287-293
have gained much importance because of their specific properties of strength and ductility. And also it has complete
austenite phase which is lead for different applications in various fields of nuclear, chemical, cryogenic and food
industries [34-36]. Hence, 304 austenitic type stainless steel are most frequently used for the corrosion resistance
applications and it can be replaced for the aggressive corrosion environments of marine applications due to their superior
qualities as like titanium and aluminum alloys. Austenitic stainless steel has excellent weldability owing to their low
alloy contents and one of the major drawback is that the fusion welding of these alloys have resulted in formation of
several defects and can destroy the austenite phase and consequently the formation of solidification cracks. Moreover, the
joining of these steels with other materials to extend their usage for various applications considered to be more important.
One of the most important applications of 304 austenitic stainless steel with D3 tool steel found various applications. The
combination of these joints exhibits several issues while joining, and the formation of intermetallic compounds various
microstructural changes during fusion welding. The microstructural characteristics revealed the presence of coarser
grains near to the weld interface which can deteriorate the mechanical properties and corrosion properties of the welds
[17, 24]. The microstructural studies on these alloy joints identified the thermal mismatch in microstructural changes
during friction welding [19, 37]. Moreover, the investigations on dissimilar combinations of high speed steel to medium
carbon steel by friction welding assessed the influence of experimental conditions which are suitable for the achieving
required service applications. The friction welding was carried out using different combinations of welding parameters.
The welding parameters combinations are optimized using design of experiments techniques and produced the friction
welded joints. The produced joints were heat treated to improve the joint properties and characterized using dynamic
torsion methods [21, 38]. The effect of welding conditions have more impact on the strength of the joints. The
mechanical and metallurgical properties of D3 tool steel are quite similar to 304 stainless steel and its combination of the
friction welded joints are widely used in many applications. The friction welding of austenitic stainless steel to D3 tool
steel studies have been investigated and reported that the strength of the joints were strongly depends on the proper
selection of welding conditions for enhancing the mechanical properties [16, 39].
However, the properties of a 304 austenitic stainless steel and D3 tool steel dissimilar combinations are have not yet been
friction welded to evaluate the influence of welding conditions on their joint properties. The present study is aimed at to
identify the effect of welding conditions combinations for producing joints with higher mechanical properties. To
understand the welding conditions behavior on microstructural changes and mechanical properties of the dissimilar
joints. Also the results hence would provide feasibility range of welding conditions to obtain the highest joint strength at
different welding parameters.

II. EXPERIMENTAL PROCEDURE

The base materials of AISI 304 austenitic stainless steel and D3 tool steel with diameter of 16 mm were cut to the length
of 100 mm for the friction welding joints. The mechanical properties of the 304 stainless steel and D3 tool steel materials
were: tensile strength 546 MPa and 648 MPa, and the elongation 65% and 21% respectively. To get the accuracy of the
joint strength of the all welds, before welding of base metal substrates faying surfaces are machined and followed by
polished with 600 grit emery papers. The samples were polished until to get the required surface roughness, which has
more contribution on the enhancing bond strength of the welds. All the samples were cleaned with acetone and dried to
remove the oil, grease, dirt, etc. just before producing the joints. To produce the joints, continuous drive friction welding
method was used with the machine capacity of 200 kN of ETA make. To measure the axial force on the substrates and
for its control a load cell was used in this machine. In order to understand the welding conditions effect on joints, all the
important friction welding conditions such as axial load, spindle position and spindle speed are read and plotted online
during friction welding. The variation of the welding conditions of process chart helps to monitor the process behavior
and to calculate the heat input of the joints. Fig. 1 illustrates the present study process chart of the friction welding
conditions. In friction welding process, the process parameters have significant effect on the mechanical and
metallurgical properties of the welds. The welding conditions of upset pressure, friction pressure, upset time, friction
time and rotational speed have direct relation to the joint formation and its strength.

Fig. 1. The process parameters graph shows the variation of welding conditions with time.

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 Haribabu et al., International Journal of Advanced Research in Computer Science and Software Engineering 8(4)
ISSN(E): 2277-128X, ISBN: 978-93-87396-07-4, pp. 287-293
To achieve the high quality joints, a new combinations of welding parameters are optimized using design of experiment
technique. The combination of friction pressure to upset pressure, upset pressure to friction time and friction pressure to
friction time are used for optimizing the parameters. The joints were produced at these combinations to evaluate the
strength of the welds. The welding combinations are designed at a upset pressure of 140 to 180 MPa, upset time 5 sec,
friction pressure in the range of 120 to 180 MPa, friction time 2 to 5 sec and spindle of 1500 rpm was used.
After friction welding, samples were cut to make the cross sections for metallographic samples preparation the cross
section of the samples were prepared as per the metallographic procedure for microstructural analysis and hardness
measurements. The tensile samples were prepared as per the ASTM E8 standard for the evaluation of mechanical
properties [40]. The joint tensile strength was carried out by machining the weld flash using a universal testing machine
TFUC-400 India. In addition, Vickers hardness test was conducted for the joints to clarify the joint properties and
intermetallic compounds formation across the weld interface. The microstructural observations were made using optical
microscope after etching the samples with 2% nitol for D3 tool steel and aqua regia solution of 304 austenitic stainless
steel for the joint interface and microstructural formations before and after welding.

III. RESULTS AND DISCUSSION

A. Microstructure Analysis
The dissimilar metals joining using any joining methods is still challenging with the several problems of the welded
joints of stainless steel to tool steels which have excellent properties and their wide range of applications. The
characteristics of the conventional fusion weld interfaces between austenitic stainless steel and tool steel shows
solidification problems and improper boding, thus resulted in deterioration of the mechanical properties [36, 38]. To
make use of these alloys, an alternative welding techniques are found to be successful in producing sound welds and the
results are satisfy the intended service applications. Solid state welding process of friction welding is one of the
prominent welding process for producing joints between incompatible materials. The welding of the two materials very
difficult due to their different physical and metallurgical properties. The microstructure of the tool steel contains the
martensitic structure with presence of carbides and ferrites. The equi-axed grains with the twin boundary and the fully
austenite structure exhibits in the 304 austenitic stainless steel microstructure. The two distinct microstructures of two
different alloys makes the weldability poorer and subjected to several solidification problems in the fusion zone,
therefore mechanical properties of the welds deteriorates across the brittle phases.

Fig. 2. The microstructure of the weld interface showing the deformation zones on tool steel side.

The faying surfaces of the substrates frictionally rub each other during friction welding and generates the heat between
the two surfaces and subjected to deformation. The weld flash formation due to deformation on the D3 tool steel side is
higher than the 304 SS side. The properties of the tool steel changes with temperature, due to this, its most of the
applications are restricted below 250 ˚C. Whereas, the deformation on stainless steel side is very less compared to D3
tool steel. The microstructures of the cross section of the joints at weld interface are depicted in Fig. 2. The image shows
the occurrence of plastic deformation adjacent to the weld interface which resembles as unetched region with the
presence of finer grains. During welding, the material subjected to heat and pressure, thus the softened region of the
material experienced to the formation of dynamic recrystallization zone (DRX) and the grains are refined to form as fine
grain structure. The material flow in this region is inclined to the weld interface and its structure is modified from the
base metal. The microstructure on the stainless steel illustrates very small region of dynamic recrystallization unlike tool
steel. The weld interface at center regions is smooth and the formation of very thin interfacial layer has been observed.
Whereas, the weld interface at the periphery of the joints exhibits different from the center region with the formation of
several width of interface. The relative speed and its effect at the periphery region is higher than the center region thus
the width of intermixing zone formation is higher at the periphery region.

B. Mechanical Properties
The micro hardness profiles taken from the transverse direction of the welds at center region of the joints, are depicted in
Fig. 3. The highest hardness value obtained at the weld interface near to the tool side weld interface. The hardness values
are gradually increased towards interface from the base metal, and the highest hardness at adjacent to the weld interface
subjected to the strain hardening affect and the formation of finer grains
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 Haribabu et al., International Journal of Advanced Research in Computer Science and Software Engineering 8(4)
ISSN(E): 2277-128X, ISBN: 978-93-87396-07-4, pp. 287-293

Fig. 3. The micro hardness of the friction welded joints.

Fig. 4. The 3-D contour graph illustrates the effect of upset pressure and friction pressure on tensile strength of the joints.

in the dynamic recrystallization zone (see fig. 2). The hardness profiles shows the significant difference that the highest
profile recorded for the interface, it is due to the formation intermixing zone. It is expecting that the intermixing zone
consists of presence of hard and intermetallic compounds. As analyzed in microstructural images, the weld interface at
periphery region owing to the cause for recording highest hardness. The large difference in hardness values of center and
periphery regions shows that the failure region and crack initiation occurring from the intermixing zone at periphery of
the weld joints. Figure 4 illustrates the 3-D contour graph of the effect of friction pressure and upset pressure on tensile
strength of the joints. The combination of these two parameters has considerably have effect of improving mechanical
properties. As the friction pressure and upset pressure increasing the raise in strength of the joints is very less initially
and its starts to increase from the friction pressure of 150 MPa. At the same time the upset pressure also shown
significant impact on improving strength and it is gained the importance after

Fig. 5. The 3-D contour graph illustrates the effect of upset pressure and friction time on tensile strength of the joints.

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 Haribabu et al., International Journal of Advanced Research in Computer Science and Software Engineering 8(4)
ISSN(E): 2277-128X, ISBN: 978-93-87396-07-4, pp. 287-293

Fig. 6. The 3-D contour graph illustrates the effect of friction pressure and friction time on tensile strength of the joints.

reaching its value to 170 MPa. However, the combination of these both parameters considerably have high effect on
improving strength and reached its value to 318 MPa. The effect of friction time is alone achieved maximum strength
with increasing its value from 2 to 5 seconds. In order to identify its effect with other parameters, upset pressure and
friction pressure were selected and optimized. The strength of the welds of these another two combinations shows quite
different from the friction and upset pressures combinations. The differences in strength using other two combinations
with friction time clearly revealed the importance of friction time in friction welding to achieve the sound welds. Figure 5
exhibits the 3-D contour graph for the combination of upset pressure and friction time with tensile strength of the joints.
The graph obtained from the upset pressure and friction time combinations are entirely different from the other two
combinations. The extension of width of the tensile strength range and level is narrow with increasing of upset pressure
and friction time. In this combination, the maximum strength of 309 MPa achieved for the joints. The decrease in
strength of the joints is due to the effect of improper combination of the welding parameters. The effect of upset pressure
and friction time both have reduction of material and contributes to plasticize the materials surfaces during welding. Due
to this effect, the joints weld flash formation is increases and the metallurgical binding is in weak formation between the
two surfaces. As the upset pressure increases, the increase in axial load gradually increases and at the same time the
effect of friction time helps to grow the weld flash, consequently it impairs the strength of the welds.
The tensile strength of the combinations of friction pressure and friction time illustrated in Fig. 6. The strength of the
joints increased and achieved maximum strength for this combination. The effect of friction pressure showed much
importance for the dissimilar combination of tool steel and austenitic stainless steels. As the tow substrates quite harder,
then the friction time needs to be increased up to certain level after that the combination of other parameters need to
support to improve the joints. The combination of friction pressure and friction time achieved the maximum strength of
320 MPa for the dissimilar materials of tool steel and 304 stainless steel.

IV. CONCLUSIONS
The dissimilar materials of 304 austenitic stainless steel and D3 tool steel was successfully joined by using friction
welding process. The feasibility of the joining of these materials using friction welding and welding conditions are
studied extensively. The joint microstructural characteristics, weld interface and mechanical properties are evaluated. The
welding parameters are optimized using different combinations of welding conditions. Some conclusions can be drawn as
follows:
 Friction welding conditions of friction pressure, friction time, upset pressure and upset time are used for
different combinations to produce the high strength welding joints.
 The combination of friction pressure and friction time showed the best combination to achieve the high
efficiency of the joints.
 The strength of the D3 tool steel and 304 stainless steel joints achieved the maximum strength than the other
welding methods.
 The bond interface is smooth and no evidence of defects and cracks formation along the interface.
 The micro hardness of the welds increasing near to the bond interface due to the strain hardening effect and the
presence of fine grains on the weld interface.
 The optimized welding conditions of friction force and friction time achieved the maximum tensile strength of
the joints.

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