International Research Journal of Engineering Science, Technology and Innovation (IRJESTI) (ISSN-2315-5663)

Vol. 2(4) pp. 65-74, July, 2013

Available online http://www.interesjournals.org/IRJESTI
Copyright 2013 International Research Journals

Full Length Research Paper

Mechanical and Microstructure Properties of 304

Stainless Steel Friction Welded Joint
1*
Hussein Mesmari and 2Fawzia Krayem
*1
Department of Materials and Metallurgical Engineering, Tripoli University, Libya
2
Research and Development Center, Libya
*Corresponding Author E-mail: [email protected]
Accepted 26 June, 2013

In friction welding, the joints are formed in the solid state by utilizing the heat generated by friction,
followed by compressive forging force. The continuous drive friction welding method (CDFW) appears
to be an alternative to make use of stainless steel more widespread. This method is adopted in the
3
present work, and Taguchi array L27 (3 ) orthogonal array is designed for conducting the experiments
and from ANOM analysis and S/N ratio, the best set-up of operating parameters to produce AISI 304/304
stainless steel joints, these parameters was found as: P1=73.8 bar, P2=85 bar, and t1=1 sec, where t1 is
the most influential factors on weld strength. The coupling effect of these parameters has a major effect
on produced joint quality. The joined strength is with maximum efficiency of 105% that indicates, the
austenitic stainless steel is highly tolerant to friction welding. Dynamic recrystallization is the major
mechanism for the microstructural evolution at the joint centreline, which characterized by refined,
equiaxed, and homogeneous microstructure.

Keywords: AISI 304, Dynamic re-crystallization, Friction welding, Taguchi array analysis, Tensile strength.

INTRODUCTION

Stainless steel is an important engineering material with al., 2005; Murti and Sundarasan 1983; Kim et al., 2003;
multiple applications. For engineering processing, the Sahin et al., 1996). Dennin 1979, presented the first
requirement for welding techniques is preferable to attempt to establish welding parameters for new
preserve the desirable properties of such steel, as applications by numerical calculations without performing
corrosion resistance, high strength and ductility, welding trials. Taguchi statistical design was developed
formability and good appearance. Any welding defect to use a small number of experiments with simplicity of
such as sensitization, delta ferrite phase, sigma phase data analysis based on statistical tools
and stress-corrosion cracking is desirable to be (Lakshminarayanan and Balasubramanian, 2008; Vidal et
eliminated. This elimination can be achieved by friction al., 2009) The effect of FW parameters on the
welding (FW) due to the short time and rapid cooling of microstructures and mechanical properties of the weld
the process (Mumin, 2007). FW as a solid state welding joint is still a matter of investigation, where the influence
by means, motion of two faying surfaces is generates of individual parameters is the key to decide the nature of
heat, and below melting temperature compressive force the control to be established on production (Vidal et al.,
applied to make welded joint (Zhou et al., 1995). The 2009) The published study on similar stainless steel is
quality of weld joints is influenced by many parameters scarce. P. Sathiya et al. have demonstrated in a series of
such as, rotational speed (N), friction pressure (P1), work, a promising feasibility of the process to join AISI
forging pressure (P2), friction time (t1) and forging time 304 austenitic stainless steel (Sathiya et al., 2005,2008;
/duration of the forging force (t2). Many researchers have Lakshminarayanan and Balasubramanian, 2008 and
investigated the effect of friction welding parameters on Sammaiah et al., 2010). To describe the micro-structural
the quality of steel joints (Ananthapadmanaban et al., features of FW joint regarding the similar metals, it is
2009; Sathiya et al., 2005,2007; Insu et al., 2000,2002), convenient to adopt the nomenclature employed by
the optimization of parameters is studied by using Uenishi et al., 2000; Midding and Grong, 1994 these
conventional techniques (Mumin, 2007; Satyanarayana et includes by name; region I, the fully plastically deformed
66 Int. Res. J. Eng. Sci. Technol. Innov.

region (PZ) on the either side of the weld interface, which Selected Parameters: In this study, N and t2 are kept
contains small re-crystallized grains, region II where the constant. The other parameters such as P1, P2 and t1
grains are partly deformed (PDZ) by the action of forging varied within the range available in the machine setting,
pressure, with coarse grains structure, and region III the the best parameters range is shown in table (2).
unreformed (UZ) base material microstructure. Uenishi et Chosen orthogonal array (OA) for experiments: The
al., 2000 indicated that, the change in region I (PZ) selection of any appropriate set of input parameters for
microstructure is related to both, dynamic re- friction welding indicated in table (3) to evaluate for
crystallization and dynamic recovery as a mechanisms optimum tensile strength the parameter combinations of
for the micro-structural evolution of material at the joint A, B, and C are adopted to yield the best joint strength
centre line in rotary friction welds, and in the plasticized among all possible combinations.
region formed during friction stir welding. By assuming The welding parameters are coded as (1), (2) and (3)
the materials in the contact region are treated as a highly that correspond to the low, medium and high levels are
viscous fluid, North et al., 1998 modeled, the width of arranged in the OA, The parameters level ranges are
(PZ) in similar friction welds is inversely proportional to presented in table (4).The result obtained from L27
the applied P1. According to Ellis, 1972, welds made at orthogonal array are recorded and used for analysis.
higher pressures P1 show a narrower (PZ) region. Metallographic Examination: For this examination, each
Mumin, 2007; Sathiya et al., 2005,2007; Mumin et al., sample was mechanically cut from both sides of the weld
2007 concluded that, for AISI 304 FW joints also exhibit a joint, split longitudinally by wire cut, and the final shape and
comparable strength with the base material, and the joint dimensions are presented in figure (1). All specimens were
strength decrease with the increase in the t1. Mumin, metallurgicaly polished and etched with a suitable agent (10
2007, has shown, the tensile strength of the joints ml HNO3, 10 ml acetic acid, 15 ml HCl, 2 to 5 drops
glycerol), then examined with optical microscope.
increases with t1, as it rises to a maximum, and then
Tensile Test: These tests were carried out in order to
decreases for longer t1. The strength of the joints was
evaluate the tensile strength of joints. After turning off
found to decrease, as t1 of the joints is increased more
flashes, standard samples were machined, and weld
than the optimum value. Other authors (Sammaiah et al.,
interface kept at mid gage length as possible.
2010; Sujith, 1999; Sare and Ismail, 2009; Kato and
Tokisue, 1994; Michael, 1992), assure that, tensile
strength tends to be improved with an increase in P1, and
RESULTS AND DISCUSSION
also reported, in order to obtain joint strength equivalent
to the base material, it is recommended to set a fairly
Features of the Joint: according to the pre-selected
high P2 without any excessively long t1 or high P1. Kato
condition and setup parameters, the flash obtained in all
and Tokisue, 1994, found that tensile strength tend to be
welded samples exhibited symmetrically shaped flash
improved with an increase in the P1 and t1. In the
and the plastic deformation shaped in a homogenous
present study, similar stainless steels AISI 304 were
way for both stationary and fixed parts, as in figure (1).
directly friction welded, and the tensile strength is taken
Microstructure of the Joints: the optical
as a main evaluation of joint efficiency and P1, P2, and t1
microstructures are shown in figure (2), a number of
are taken as parametric design for Taguchi analysis to
different microstructure regions are located relative to the
optimize the best welding setup.
bondline. A finer grain structure observed in PZ, where at
PDZ consists of coarser grain structure. Within the PZ,
the direction of original elongated grains gradually rotates
MATERIALS AND EXPERIMENTAL PROCEDURES
through 90 to bar axis. These fine grains are present on
both sides of friction plane, i.e. in the area of the most
The chemical composition and average tested tensile
intensive friction where dynamic re-crystallization (DRX)
strength of used steel are shown in table (1).
took place, and this founding is clearly appeared in all
The received material used are cylindrical bars of 200
welded samples, as in figure(3). Sathiya et al.,
mm in length, and 25 mm in diameter ,the samples were
2005,2008;2004 also have observed fine grained
stress relieved to a temperature of 350C for 1 hour
followed by still air cooling. Prior to friction welding, the
structure in the PZ in AISI 304 welding stainless steel.
mating faces of all samples were machined perpendicular to This can be interpreted as the FW involves heavy plastic
the rotational axis, and then cleaned with acetone just working at higher temperatures close to the melting point
before welding. of the base materials. This plastic deformation introduces
Design of experiment and Friction welding: All large number of dislocations in the materials. As the
welding was conducted on a continuous drive rotary density of these dislocations increases, they tend to form
friction welding machine, a number of parameter sub-grain cell structure. These low-angle grains rotate
variations are obtained according to Taguchi statistical to form high-angle strain free grains resulting in a zone of
design. After welding, the joints were cooled in very fine equiaxed grains compared to the base
still air, followed by wire cutting and prepared for further materials, referred to as DRX grains, this proposition
mechanical and optic-metallographic investigations. also reported by Dey et al., 2009. In the present work, the
 Hussein and Fawzia 67

Table 1. The Chemical Composition and Tensile Strength

Material C Si Mn P S Cr Ni Fe UTS , MPa

AISI 304 0.041 0.35 1.36 0.026 0.024 18.8 8.21 Bal. 653

Table 2. Best parameters range

Join Type P1 bar P2 bar t1 sec t2 sec N rev/min

AISI 304/304 63.5 85 1 1.79 931

Table 3. Input parameters of friction welding

Parameter Unite Designation

Friction pressure,P1 bar A
Forging pressure, P2 bar B
Friction time, t1 sec C
Forging time, t2 sec D
Rotational speed, N rmp/min E

Table 4. The best welding parameters and their levels

Level
Symbol Parameter
Low (1) Medium (2) High (3)
A P1, bar 53.8 63.8 73.8
B P2, bar 70 85 100
C t1, sec 1 2 3
D t2, sec Constant = 1.79
E N, rmp/min Constant = 931

Figure 1. Configuration and dimension of metallographic sample (mm).

68 Int. Res. J. Eng. Sci. Technol. Innov.

a. Microstructural development at the bondline and welding zones, 50X

Weld
Direction of interface
weld interface

b. Region I (PZ) at 500X

c. Region II (PDZ) at 500X d. Region II (UZ) at 500X

Figure 2. Microstructures at different zones.

DRX

Weld Interface
Figure (3). Refine grains on both sides of the bondline.
Figure 3. Refine grains on both sides of the bondline 500X.
 Hussein and Fawzia 69

Interface
Flash direction

Near the flash At Peripheral part At the center

Figure 4. Deformed region widths of the peripheral and central region FW joint, 50X

UZ PDZ PZ

Weld Interface

UZ PDZ (0.50mm) PZ (1 mm) PDZ (0.56mm) UZ

mm)
Figure 5. Axial section microstructure morphology mm)
(a)-100X and (b)-300X

effect of t1 on DRX clearly appears where the width of Figure (5) shows the microstructure of PZ at
the DRX increased from the central to the peripheral approximately 1 mm from the bondline, the PDZ
region as the friction time increased. At the edge of the approximately 0.5 mm width, and the (UZ) is found at 1.5
peripheral part, the DRX region was narrowed again mm away from the bondline. These measured results are
because of the formation of the flash outside the interface. In well complied with finding of Sathiya et al., 2008; Insu et
contrast, as the t1 increased, the width of region PDZ tends al., 2000 and Sathiya et al., 2005,2008 have observed;
to be reduced. Since the hot metal is squeezed out during as the t1 increased, the PZ become broader, and in
the forging process the boundaries of the HAZ moves contrast, as the t1 increased, the width of region PDZ
towards the interface. Thus the width of the weld metal tend to be reduced. Table (5). summarize the
becomes broader when increasing t1, as in figure (4). microstructures zones and how space from bondline.
70 Int. Res. J. Eng. Sci. Technol. Innov.

Table 5. Friction welds Microstructural zones.

Microstructural Zone Distance from bondline Grain morphology

PZ 0-0.5mm Very fine Grains parallel to bond line
Grains slightly elongated parallel to
PDZ 0.5-1.0 mm
bond line
UZ Corse Grains elongated parallel to
>1.5 mm
extrusion direction.

Table 6. The effect of P1 on tensile strength and joint efficiency ( %) joints

Specimen No. P1, bar P2, bar t1, sec UTS, MPa %
S4 53.8 85 1 633.300 96.93
S13 63.8 85 1 686 105
S9 53.8 100 3 629.400 96.34
S18 63.8 100 3 673.700 103

Main Effects Plot for Means

Data Means

P1 P2
670

665

660

655
Mean of Means

650

53.8 63.8 73.8 70 85 100

t1
670

665
660

655

650

1 2 3

Figure 6. Main effects plot for Means of AISI 304/304 joint.

Tensile Test: tensile strength is the main characteristic parameters that have notes able effect on the strength of
evaluation considered in present study to identify the the weld joint that was statistically calculated. Analysis of
quality of FW joints. From the obtained tensile strength mean for each runs gives better combination of
data for the OA L27 welded joints. it was found that, the parameter levels, which is well matching with
highest strength are obtained in all runs with average (Lakshminarayanan and Balasubramanian, 2008; Vidal et
efficiency of 100.73 % which indicates, the stainless steel al., 2009 Yi et al., 2009) results. The optimal level of
is tolerant of FW and the CDFW method can successfully process parameters is the level of highest S/N ratio in the
be adopted for performing weld joints of AISI 304. Thus, experimental region according to the larger the better
considerably, the strength of friction processed joints type. From the analysis of obtained results as shown in
exhibited comparable strength with the base material as figure (6) and in figure (7) for the mean and S/N ratio
concluded in previous studies (Mumin, 2007; Sathiya et indicates that, the optimized tensile strength obtained at
al., 2005;Mumin et al., 2007) and the highest tensile condition when: P1 (level C), 73.8 bar; P2 (level C), 100
strength was acquired as 686 MPa for the joint with the bar; and t1 (level A), 1 second.
setup conditions of; P1(63.8 bar) , P2 (85 bar), and t1 (1 Effect of Friction Pressure P1: Table (6) shows the
second). P1 has a good effect on joints strength, tensile strengths
Analysis of the Means (ANOM): the effect of the is directly improved as the P1 increased. The mean effect
individual selected parameters was investigated, as well as in figure (6) and S/N ratio in figure (7), shows the
as the combined effect of interaction of the two matching manner of effect, where as P1 increased, the
 Hussein and Fawzia 71

Main Effects Plot for SN ratios

Data Means
P1 p2
56.5

56.4

Mean of SN ratios
56.3

56.2
53.8 63.8 73.8 70 85 100
t1
56.5

56.4

56.3

56.2
1 2 3

Signal-to-noise: Larger is better

Figure 7. Main effects plot for S/N ratio of AISI 304/304 joint.

higher the strength value is obtained, and all strength of increased improvement in the quality of welded joints,
the welds varies with the P1 setting. The progressive Vill, 1962 recommended that, t1 has to be carefully
increase of the strength observed when P1 range from selected, and its desirable to have short heating times for
63.8 to 73.8 bar, due to the formation of narrow softened better results. From table (8) it can be seen that, the
region along the bondline. Therefore, the present result obtained strength data represents a similar effect of t1 on
as shown in the mentioned figures provides well support joints strength, where parameters are slightly reduced,
to (North et al., 1998) founding. A mathematical model with an estimated percentage of increase by 9% when
has been proposed by North et al., 1998, and others the t1 increased from 1 to 3 seconds. These founding is
(Uenishi et al., 2000; Sujith, 1999) agreed with this in a good agreement with results Sathiya et al., 2005,
model, by assuming that the materials in the contact 2008.
region are treated as a highly viscous fluid, and the width The both figure (6) and (7) show that, as the t1
of the fully plasticized region in similar friction welds are increases the tensile strength drop off, and as the friction
found to be inversely proportional to the applied P1. This time held for 1 sec, weld strength raises to maximum
is well confirmed with the present results. values. The reason for the strength and quality values
Effect of Forge Pressure P2: The general trend of the drop can be attributed to the change in the amount of
obtained strength data P2 is appeared to increase in a heat generated during the process lead to grain
range of variations from 588.8 MPa to 686 MPa for coarsening and consequent reduction in strength of
specimens S11 and S13, respectively as the P2 weldment. Therefore, interface temperature increase,
increased from 70 to 100 bar, some of other joints data results a softening of the metal at that region. The
tabulated in table (7), reveals, the P2 has an excellent formation of wide softened regions adjacent to the
influence on strength of the joint efficiency which related bondline associated with the reduction in tensile strength.
to the amount of metal deformed and flowing out. Many A different way of behavior was developed when the t1
authors (Sujith, 1999; Sare and Ismail, 2009; Michael, rose to 3 seconds; this reverse approach may be
1992; Pinheiro, 2008) reported that, in order to obtain attributed to an increased amount of softened metal flown
joint strength equivalent to the base material, it is out as a flash, which produced an increase in joint
recommended to set a fairly high P2 without any strength. Mumin et al., 2007 has shown a similar
excessively long t1 or high N. approach.
From the mean effect and S/N ratio figure (6), and (7) it Interactions of Design Parameters: the interaction
is clearly show, the joint strength increases as the P2 is plots of means and S/N ratios are shown in Figure (8)
increased, but this improvement in strength is clearly and (9), which indicate a strong interaction between P1
observed when P2 is increased from 70 to 85 bar. and the other two parameters: P2 and t1. With little
Between 85 up to 100 bar weld strength there is less indication between P2 and t1 which is well-known as
significant effect observed. coupling effect. The degree of effect of individual
Effect of Friction Time t1; in order to obtain an parameter on weld strength is higher in a sequence of
72 Int. Res. J. Eng. Sci. Technol. Innov.

Table 7. Effect of forging pressure on tensile strength and joint efficiency

Specimen No. P1, bar P2, bar t1, sec UTS, MPa %
S11 63.8 70 2 588.800 90.12
S14 63.8 85 2 633.800 97
S14 63.8 85 2 633.800 97

Table 8. Effect of friction time on tensile strength and joint efficiencies.

Specimen No. P1, bar P2, bar t1, sec UTS , MPa %
S13 63.8 85 1 686 105
S14 63.8 85 2 633.800 97
S15 63.8 85 3 628.400 96

Interaction Plot for Means

Data Means
70 85 100

680 P1
53.8
660 63.8
P1 73.8
640

680 P2
70
660 85
P2 100
640

680 t1
1
660 2
t1 3
640

53.8 63.8 73.8 1 2 3

Figure 8. Interaction plots for Means of AISI 304/304 joint.

Interaction Plot for SN ratios

Data Means
70 85 100

P1
56.50 53.8
63.8
56.25 P1 73.8

56.00
p2
56.50 70
85
p2 56.25 100

56.00
t1
56.50 1
2
56.25 t1 3

56.00

53.8 63.8 73.8 1 2 3

Signal-to-noise: Larger is better

Figure 9. Interaction plots for S/N ratio of AISI 304/304 joint.

 Hussein and Fawzia 73

effect: t1, P1 and P2. Processing Technology.

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Sathiya P, Aravindan S, Noorul A (2008). Some experimental
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the Eng. Salah A. Elfarrah. Also the technical support of Sathiya P, Aravindan S, Noorul A (2004). Friction welding of austenitic
Mr. T. S. BABU is deeply appreciated. The authors would stainless steel and optimization of weld quality ISRS, Vol. 20, NO.
like to thank Eng. Mariam M. Morgham, Eng. Mohammed 22, 110.
Sathiya P, Aravindan S, Noorul A (2005). Mechanical and metallurgical
Twabi and Eng. Hassan Alsadawy, for their assistance
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during experimental part of this study. Adv. Manuf. Technology, Vol. 26, 505511.
Sathiya P, Aravindan S, Noorul A (2007). Effect of friction welding
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