Materials and Design 30 (2009) 135144

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Materials and Design

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Characterization of properties in plastically deformed austenitic-stainless steels joined by friction welding

Mumin Sahin *
Mechanical Engineering Department, Engineering and Architecture Faculty, Trakya University, 22180 Edirne, Turkey

a r t i c l e

i n f o

a b s t r a c t
Friction welding is widely used as a mass-production method in various industries. Welding is used for joining parts with equal and/or different diameters. Austenitic-stainless steels are preferred over other stainless steels due greater ease in welding. In the present study, an experimental set-up was designed in order to achieve friction welding of plastically deformed austenitic-stainless steels. AISI 304 austenitic-stainless steels having equal and different diameters were welded under different process parameters. Strengths of the joints having equal diameter were determined by using a statistical approach as a result of tension tests. Hardness variations and microstructures using scanning electron microscope (SEM) analysis in the welding zone were obtained and examined. Subsequently, the effects on the welding zone of plastic deformation was analysed. It has been established that plastic deformation of AISI 304 austenitic-stainless steel has neither an effect on the process nor on the strength of the welding joint. 2008 Elsevier Ltd. All rights reserved.

Article history: Received 18 October 2007 Accepted 16 April 2008 Available online 22 April 2008 Keywords: Materials joining Welding

1. Introduction Stainless steels are iron-based alloys containing 825% nickel and 1230% chromium. Such steels resist both corrosion and high temperature. Generally, stainless steels can be classied as martensitic, ferritic and austenitic. Austenitic-stainless steel is preferred over other stainless steels because of ease in both welding and deformation. However, negative metallurgic changes are also involved in the welding of steels. On the other hand, friction welding is known to eliminate these negative effects due to limited time and rapid cooling in working. Therefore, friction welding is more advantageous than other welding methods. Friction welding involves generation of heat by the conversion of mechanical energy into thermal energy at the interface of the work pieces without using electrical energy or heat from other sources during rotation under pressure. Friction welding provides considerable savings in materials, low production time and the possibility of the welding parts made from different metals or alloys. The most important parameters in friction welding are friction time, friction pressure, forging time, forging pressure and rotation speed. Friction welding is classied into two as continuous drive friction welding (1) and inertia friction welding (2) [2,3]. Experimental set-up used in the present study is of the continuous drive type. In this method, one of the components is held stationary while the other is rotated at constant speed (s). The two components are
* Tel.: +90 284 2261217; fax: +90 284 2261225. E-mail address: mumins@trakya.edu.tr 0261-3069/$ - see front matter 2008 Elsevier Ltd. All rights reserved. doi:10.1016/j.matdes.2008.04.033

brought together under axial pressure (Pf) for a given friction time (tf). Then, the clutch is separated from the drive, and the rotary component is brought to a stop within the braking time while the axial pressure on the stationary part is increased to a higher forging pressure (Pu) for a predetermined upset time (tu). The parameters of the method are shown in Fig. 1 [15]. In the inertia welding, one of the components is held stationary, while the other is clamped in a spindle chuck, usually attached to y wheels. The y wheel and the chuck assembly are rotated at a given speed (s) to store a predetermined amount of energy. Subsequently, the drive to the ywheel is declutched, and the two components are brought together under axial pressure (Pf). The friction between the parts decelerates the ywheel converting stored energy to frictional heat. Vill and Tylecote gave an overview on friction welding. Jenning examined the properties of the dissimilar materials joined by friction welding. Lucas examined the process parameters on friction welding. Kinley studied inertia friction welding [15]. Seregin and Sabantsev studied friction welding of the plastically deformed steels [6]. Ellis [7] examined the relation between friction timework-piece diameter, loss of length-forging pressure and carbon equivalent-hardness variation. Dunkerton [8] studied the effects of rotation speed, friction pressure and forging pressure in all friction welding methods used for steels. Murti and Sundaresan [9] directed a study on parameter optimisation in friction welding of dissimilar materials using a statistical approach based on a factorial experiment design technique. Nentwig et al. [10] studied the effect of differences in cross section of the components on the joint quality upon friction welding. Sahin [11] studied the effect of

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Friction Time (tf)

Braking Waiting Upset (tu)

Before Upset d0=15mm. Ho After Upset

Rotation Speed (s) Friction Pressure (Pf) Torque (T) Starting Time

Upset Pressure (Pu)

Shortening

Finishing
Fig. 2. Plastic deformation in forge parts.

Fig. 1. Parameters on continuous drive friction welding.

workpiece dimensions and plastic deformation on the accomplishment of friction welding. Akata et al. [12] directed a study on the effect of differences in dimensions in friction welding of AISI 1040 specimens. Sahin [13] investigated joining of plastically deformed carburizing steel by friction welding. Sahin [1416] also studies friction welding of medium-carbon steel and austeniticstainless steel components. The aim of the present study is to nd out whether plastic deformation has an inuence on friction welding of austeniticstainless steels. Plastically deformed parts having equal and/or different diameters were welded under different process parameters. Strengths of joints were determined by means of a statistical approach using the results of tension tests. Hardness variations in the welding zone and microstructures were examined using EDX (Energy Dispersive X-ray) analysis so as to have an insight into the phases occurring during welding at the interface. Subsequently, the effects of plastic deformation on the welding zone were investigated.
2. Experiment set-up The set-up was designed is of a continuous drive friction welding type. A drive motor with 4 kW power and 1410 rpm was found to provide adequate torque capacity for friction welding of steel bars with respect to friction and upset pressures. The set-up provides automatic transition from the friction to the forging stage.

For Wmin = 15 mm, D = 15 mm and d0 = 15 mm in Eq. (1), the maximum value for H0 can be calculated as p 252 =4 15 p 152 =4 H0 max and H0 max = 41.6 mm is found. Amount of plastic deformation (e) is [18], e ln H0 W 2

Therefore, for Wmin = 15 mm and H0 min = 15 mm, emin = ln 15/15 Thus emin 0. For Wmax = 15 mm and H0 max = 41.6 mm, emax = ln 41.6/15 Thus emax 1:02. Therefore austenitic-stainless steel parts can be obtained using different amounts of plastic deformation using the forge method. The specimen sizes used in the experiments are shown in Fig. 4. Friction time and friction pressure have a direct effect on the tensile strength of joints. Therefore, linear statistical analysis was used in order to discover the effect of factors that have a signicant role on the experimental results of previous studies [9,13,15,16,19]. The statistical analysis used in the present study is given in Section 4.

4. Statistical approach The basis of this approach is the assumption of a simplied linear model for the optimisation parameter g given by g = b0 + b1x1 + b2x2 + . . ., where x1, x2. . ., etc., are the factors on which g depends and b0, b1, b2. . ., etc., represent the true values of the corresponding unknowns. From the results of an experiment comprising a nite number of trials, one can arrive at the sample estimates of the coefcients, b, which are then usually tted into a linear regression equation of the type y = b0 + b1x1 + b2x2 + . . . , where y is the response function and the bs are the estimated values of the bs. In simple terms, each coefcient represents the inuence of the corresponding factor on the quality of the weld expressed by the optimisation parameter. A suitable method is based on the Fischer or F ratio, which can be used to conrm if the terms in the assumed linear function are statistically signicant. Then, optimal estimates of the regression coefcients are obtained for the signicant factors, which may be done using the method of least squares [9,13,19].

3. Material and geometry of specimens used in the friction welding experiments Chemical composition of the materials used is given in Table 1 [17], while dimensions of the parts and the amount of plastic deformation used are given in Figs. 2 and 3. Volume-stability for plastic deformations in Figs. 2 and 3 in austenitic-stainless steel materials can be expressed as   2 p D2 =4 W p d0 =4 H0 1 For Wmin = 15 mm, D = 15 mm and d0 = 15 mm in Eq. (1), the minimum value for H0 can be calculated as p 152 =4 15 p 152 =4 H0 min and H0 min = 15 mm is found.

Table 1 The chemical composition of the material used in the experiments [17] Material AISI 304(X5CrNi1810) %C <0.07 %P <0.045 %S <0.030 %Mn <2.0 % Si <1.0 % Cr 1719 % Ni 8.510.5 Tensile strength (MPa) 825

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Upset Part D

Machined Part 10

15

W=15
Fig. 3. Application of friction welding in upset parts.

Diameter of Rotating Work piece Obtained Plastically Deformed (Part I)

Diameter of Axially Sliding Work piece Obtained Machined (Part II)

T, s

Pf , tf

Chuck

Width of Rotating Work piece

Fig. 4. Part dimensions used in the experiments.

Table 2 Experimental results Trial no. 1 2 3 4 5 Friction pressure (MPa) x1 20 45 60 60 60 Friction time (s) x2 9 9 9 3 11 Tensile strength (MPa) y 80 700 795.8 450 750

Table 3 Optimum welding conditions Material Friction pressure (MPa) 60 Friction time (s) 9 Upset pressure (MPa) 110 Upset time (s) 20 Rotational speed (rpm) 1440

Austenitic-stainless steel

Table 4 Parameters used in the friction welding experiments

Parameter optimisation was carried out using two factors: friction time, friction pressure. Other parameters such as upset time, upset pressure and rotational speed were maintained constant. Experimental results are given Table 2. 5. Results and discussion Optimal estimates of regression coefcients were obtained using the Fisher method ratio. The resulting equation is: y 581; 696 15; 465x1 46; 226x2 3

Diameter of Friction Friction Upset Upset Width of Diameter of pressure time pressure rotating work rotating work axially work time Pf (MPa) tu (s) Pu (MPa) piece (D) mm piece (W) mm piece d (mm) tf (s) 10 15 17 18 25 15 10 9 60 20 110

The correlation coefcient using Eq. (3) is about 0.93 with respect to tensile strength. Therefore, it is quantitatively shown that the effects of friction time and friction pressure on the tensile strength are very signicant as expected. In consequence, the parameters having the least error using the method of least squares were taken as the optimum welding parameters. The optimum welding conditions are given in Tables 3 and 4. As a result, the optimum parameters were found as: friction time = 9 s, friction pressure = 60 MPa, upset time = 20 s and upset pressure = 110 MPa. Parts, which have various widths, were joined using the obtained optimum welding parameters. Later, many parts were machined and welded using these optimum parameters, and then these specimens were further tested. The strength of joints was determined by tensile tests, and the results were compared with

those of fully machined specimens. Tensile strength of the joints was estimated dividing the ultimate load by the area of the 10 mm diameter specimen. The relation between the tensile strength and specimen width is shown graphically in Fig. 5. Tensile strength of the joints decreases as the diameter ratio increases in the plastically deformed parts (Fig. 5). This result can be attributed to an increase in heat capacity due to heat loss by the rotation. Decrease in strength is related to the hardness variation within heat affected zone (HAZ). The hardness variation was obtained by the Vickers micro-hardness test under a load of 1 kg. Measuring locations are shown in Fig. 6. The hardness variations are shown in Figs. 7 and 8. Hardness in the horizontal direction decreases slightly at the central zone compared to the base metals. However, stainless steel

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Austenitic-Stainless Steel (Pf=60MPa, Pu=110MPa, tf=9sec, tu=20sec); W=15mm.

850 800 Tensile strength (MPa) 750 700 650 600 550 500 1 1.5 2 2.5
Diameter ratio (D/d) D=10,15,17,18,25mm. ; d=10mm.
Fig. 5. Relationship between the tensile strength and the width for austenitic-stainless steel.

1 1.5 1.7 1.8 2.5

Part I

Joint Centre (Midaxis)

Part II

Vertical Distance to the centre y

Austenitic-Stainless Steel (AISI 304)

300

Vickers Hardness (HV)

Horizontal Distance to the centre x

250

200

D/d=1 D/d=1.5

Fig. 6. Hardness test orientation.

150

D/d=1.7 D/d=1.8

100

D/d=2.5

has lower thermal diffusivity. Therefore, increasing heat is not removed from the interface, and thus, the interface cools later than HAZ. Grains will recrystallize at the interface of the joint due to the heat generated, thus removing the effect of plastic deformation. This is why no increase in hardness at the interface is observed though the hardness of the central zone decreases slightly. The hardness variations in the vertical distance of the joints are nearly the same as the sides of the parts compared to their centres.

50

0
0 1 2 3 4 5

Vertical Distance (mm)

Fig. 8. Hardness variation diagram in vertical direction.

Austenitic-Stainless Steel (AISI 304)

300

250

Vickers Hardness (HV)

200

D/d=1 D/d=1.5

150

D/d=1.7 D/d=1.8

100

D/d=2.5

50

0 -5 -4 -3 -2 -1 0 1 2 3 4 5

Horizontal Distance (mm)

Fig. 7. Hardness variation diagram in horizontal direction.

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Subsequently, friction welded joint cross-sections after etched in picral were subjected to a standard metallographic sample preparation technique in order to examine the microstructure using optical microscope, and the macro and microstructure of the joints were analysed. The macro photograph (x5) of the equal diameter joint is shown in Fig. 9, while the macro photograph (x3) of the different diameter joint is shown in Fig. 10. The weld ash and the contact zone can easily be observed in Figs. 9 and 10. However, for the different diameter joints, the microphotographs of both HAZ in the joints having the equal diameter and the machined parts in the joints having the equal and different diameter are shown in Figs. 11 and 12, respectively. Then, the microphotographs of the plastic deformed part (D = 25 mm) and the transition zone in the joints having the different diameter are shown in Figs. 13 and 14, respectively. Then, scanning electron microscopy (SEM) and energy dispersive X-ray (EDX) analysis were performed so as to have an insight into the phases occurring during welding at the interface. Observations were carried out using a 200 kV eld effect scanning electron microscope (SEMJEOL JSM 5410 LV microscopy) coupled to EDS (energy dispersive X-ray spectroscopy) analysis. EDS point analysis was used in the examinations. The software allowed piloting of the beam, scanning along a surface or a line to obtain X-ray cartography or concentration proles by elements, respectively. SEM

microstructure of welding metal and transition zone in the friction welded equal diameter specimens and EDX analysis results are given in Fig. 15, while distribution of elements within the

Fig. 11. The microphotograph of the machined part (d = 10 mm).

Fig. 9. The macro photograph of the equal diameter parts.

Fig. 12. The microphotograph of HAZ in welded part having equal diameter (d = 10 mm).

Fig. 10. The macro photograph of the different diameter parts.

Fig. 13. The microphotograph of the plastic deformed part (D = 25 mm) in different diameter joints (D = 25 mmd = 10 mm).

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Fig. 14. The microphotograph of the transition zone in different diameter joints (D = 25 mmd = 10 mm).

a) SEM microstructure of welding metal in different diameter joint (D=25mm to d=10mm)

Spectrum10 Fe

Fe

Cr

Cr Mo Mo Mo 0 B Al Ar Sc Cr Co Zn Mo Mo Mo Mo Mn Fe Mn Fe Ni Ni 10 Ge Se Kr Sr Zr Mo Mo Mo Mo Mo Mo 20 Ru Pd Cd Sn Te I 30 Xe Cs

Cursor=22.560 keV 0 cnt ID =

b) EDX analysis result taken according to SEM image of welding metal

Fig. 15. SEM microstructure of welding metal and transition zone in the friction welded equal diameter joint and EDX analysis results.

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141

c) SEM microstructure of transition zone in equal diameter joint

Spectrum9

Fe

Fe Cr

Mo Mo Mo Mo Mo 0 B Cursor= Al Ar Sc Mo Mo

Cr Mn Mn Fe Fe Ni Ni Ni 10 Cr Co Zn Ge Se Kr Sr Zr Mo Mo Mo Mo Mo Mo 20 Ru Pd Cd Sn Te I 30 Xe Cs

d) EDX analysis result taken according to SEM image of transition zone

Fig. 15 (continued)

Table 5 EDS point analysis results according to SEM microstructure in equal diameter joints Elements Welding metal Cr Mn Fe Ni Mo Cr Mn Fe Ni Mo Line Ka Ka Ka Ka La Ka Ka Ka Ka La Intensity (c/s) 190.89 16.05 493.30 39.83 6.22 Total 177.12 11.07 410.24 34.22 3.23 Total Conclusion (wt.%) 17.110 1.640 71.316 8.595 1.340 100.000 18.850 1.343 70.264 8.722 0.822 100.000

Transition zone

Then, Fig. 16a and c shows SEM microstructure in welding metal and transition zone of the friction welded different diameter specimens. Fig. 16b and d illustrate the EDX analysis results taken from various points of the SEM image, respectively. And, Table 6 shows the EDS point analysis results represented to SEM. As it can be seen from optical microscope and SEM microstructures, the joint microstructure is classied into three distinct regions [20]. Region I: The fully plastically deformed region on either side of the weld interface. This region contains small recrystallized grains. Region II: The region where the grains are partly deformed by the upset pressure that completes the friction welding process and grain size is larger than region I. Region III: The undeformed base material microstructure.

determined location are shown in Table 5. EDS analysis was carried out for various points of the SEM image.

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M. Sahin / Materials and Design 30 (2009) 135144

a) SEM microstructure of welding metal in different diameter joint (D=25mm to d=10mm)

S pectrum6 Fe

Fe

Cr

Cr Mo Mo Mo 0 B Al Ar Sc Cr Co Zn Mo Mo Mo M o Mn Fe Mn Fe Ni Ni Ni 10 Ge Se Kr Sr Zr Mo Mo Mo Mo Mo Mo 20 Ru Pd Cd Sn Te I 30 Xe Cs

C ursor=22.720 keV

0 cnt ID = R h kb1 C m lg1 R h kb3

b) EDX analysis result taken according to SEM image of welding metal

Fig. 16. SEM microstructure of welding metal and transition zone in the friction welded different diameter joint (D = 25 mmd = 10 mm) and EDX analysis results.

The base metals (the machined part and the plastic deformed part) and the metal in the heat affected zone consist of austenitic grain structure. When the microstructure of the plastically deformed parts is examined, it can be observed that the grains in the microstructure are elongated in the direction of deformation. However, microstructure of the welding metal has the austenitic grain structure. This zone contains recrystallized grains due to recrystallization upon heat dissipation during welding of the plastic deformed parts. Then, reduction in hardness (HAZ softening) takes place in HAZ due to coarsening of grain within heat affected zone (HAZ). However, welding strength of the joints was not affected prior to plastic deformation. Firstly, plastic deformation in the friction welding process is greater than the degree of the prior plastic deformation. Secondly, the effect of prior plastic deformation is removed as a result of recrystallization of the layers of metal in the welding zone. 6. Conclusions In the present study, plastically deformed austenitic-stainless steels (AISI 304) were welded successfully. The welding process

was investigated by statistical analysis, tensile testing, microstructural observation, EDS measurements and hardness testing. As a result: Statistical analysis is an economical and reliable method for optimising welding parameters. Maximum strength in the joints having equal diameters has about 96% that of base austenitic-stainless steel parts. Tensile strength decreases as the diameter ratio of the joints increases. Heat that is adequate to provide the necessary welding strength in joining the parts with different diameters should be obtained by using different parameters. Hardness variations in the horizontal direction of plastically deformed AISI 304 austenitic-stainless steels have no hardening effects. Hardness variations in the vertical distance of the joints are nearly the same as the sides compared to the centre. Friction welding improves the grains in the microstructure. However, the renement of the grains occurred at the welding region due to the combined effect of thermal and mechanical stresses.

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c) SEM microstructure of transition zone in different diameter joint (D=25mm to d=10mm)

Spectrum4 Fe

Fe

Cr

Cr Mo Mo Mo 0 B Al Ar Sc Cr Co Zn Mo Mo Mo Mo Mn Mn Fe Fe Ni Ni Ni 10 Ge Se Kr Sr Zr Mo Mo Mo Mo Mo Mo 20 Ru Pd Cd Sn Te I 30 Xe Cs

Cursor=22.160 keV 0 cnt ID = Ag ka1

d) EDX analysis result taken according to SEM image of transition zone

Fig. 16 (continued)

Table 6 EDS point analysis results according to SEM microstructure in different diameter joints (D = 25 mmd = 10 mm) Elements Welding metal Cr Mn Fe Ni Mo Cr Mn Fe Ni Mo Line Ka Ka Ka Ka La Ka Ka Ka Ka La Intensity (c/s) 197.03 10.13 478.69 41.72 3.53 Total 242.29 17.86 602.23 45.93 4.32 Total Conclusion (wt.%) 18.090 1.059 70.864 9.209 0.779 100.000 17.840 1.498 71.736 8.161 0.765 100.000

Acknowledgement Author would like to thank Prof. Dr. H. Erol AKATA, Trakya University/Edirne, Hema Industry/erkezky and Metall. and Mater. Eng. Dept. of Yildiz University/Istanbul, Turkey for the help provided in this research. References
[1] Vill VI. Friction Welding of Metals. AWS. New York; 1962. [2] Tylecote RY. The solid phase welding of metals. London: Edward Arnold (Publisher) Ltd.; 1968. p. 1150. [3] Jenning P. Some properties of dissimilar metal joints made by friction welding. Advances in welding processes, solid phase joining processes. In: Proceeding of the conference, The Welding Institute, Cambridge: Abington Hall; 1971. p. 14752. [4] Lucas W. Process parameters and friction welds. Met Const Br Weld J 1971:2937. [5] Kinley W. Inertia welding: simple in principle and application. Weld Met Fab 1979;10:5859. [6] Seregin SA, Sabantsev VP. The friction welding of plastically deformed steel. Weld Prod 1975:345. [7] Ellis CRG. Friction welding: some recent applications of friction welding. Weld Metal Fab 1977;5:20713.

Transition zone

It has been established that plastic deformation of AISI 304 austenitic-stainless steel does not have an inuence on the process variables of friction welding or on the welding joint strength.

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M. Sahin / Materials and Design 30 (2009) 135144 [14] Sahin M, Akata HE. An experimental study on the friction welding of medium carbon and austenitic stainless steel components. Ind Lub Tribo 2004;56(2): 1229. [15] Sahin M. An investigation into joining of austenitic-stainless steels (AISI 304) with friction welding. Ass Auto 2005;25(2):1405. [16] Sahin M. Evaluation of the joint-interface properties of austenitic-stainless steels (AISI 304) joined by friction welding. Mat Des 2007;28(7):224450. [17] Metals Handbook, 8th ed., vol. 1. [18] Lange K. Handbook of Metal Forming 1985. [19] Draper NR, Smith H. Applied regression analysis. second ed. John Wiley and Sons; 1981. [20] Sathiya P, Aravindan S, Noorul Haq A. Mechanical and metallurgical properties of friction welded AISI 304 austenitic stainless steel. Int J Adv Manuf Technol 2005;26:50511.

[8] Dunkerton SB. Toughness properties of friction welds in steels. Weld J 1986;8: 193201. [9] Murti KGK, Sundaresan S. Parameter optimisation in friction welding dissimilar materials. Met Const 1983;6:3315. [10] Nentwig AWE. Friction welding of cross section of different sizes. Schweissen und Schneiden/Welding Cutting 1996;48(12):2367. [11] Sahin M. Investigation of the effects of the workpiece dimensions and plastic deformation on friction welding method. Graduate School of Natural Applied Sciences of Trakya University, Doctoral Dissertation. Edirne: Turkey; 2001. [12] Akata HE, Sahin M. An investigation on the effect of dimensional differences in the friction welding of AISI 1040 specimens. Ind Lub Tribo 2003;55(5): 22332. [13] Sahin M, Akata HE. Joining with friction welding of plastically deformed steel. J Mat P Tech 2003;142(1):23946.