Microstructure and mechanical properties in dissimilar friction stir welding of 316 stainless steel to 4140 steel

Document Type : Research Paper

Authors

1 Department of Mechanical Engineering, Shahid Rajaee Teacher Training University (SRTTU), Lavizan.

2 School of Metallurgy and Materials Engineering, College of Engineering, University of Tehran, P.O. Box 11155-4563, Tehran, Iran.

Abstract

In the current study, 316 stainless steel and 4140 steel sheets were successfully joined using friction stir butt welding (FSBW). The tool's rotational speed and the linear welding speed were assumed to be 1400-1700 rpm and 30-50 mm/min, respectively. The weld microstructures were examined by X-ray diffraction (XRD), optical microscopy, and scanning electron microscopy (SEM). In this welding, three zones with different structures relative to the base metals, including thermomechanical zones for each base metal and stir zone, were formed. Observations indicated that in the microstructure of 4140 steel containing martensite, the martensite blades vanished, and the grains extended in the thermomechanical zone. Furthermore, in the 316 stainless steel containing austenite, the austenite grain size was shrunk due to the dynamic recrystallization in the thermomechanical zone. Also, the microhardness test results showed that the stir zones have higher hardness than base metals in all specimens because of the dynamic recrystallization and fine-grained structure. Moreover, the 1550 rpm - 40 mm/min welded specimen in the stir zone has the highest yield strength of 350 MPa in the tensile test, which was higher than the yield strength of 316 stainless steel.

Keywords


  1.  

    1. Mvola B, Kah P, Martikainen J. Dissimilar ferrous-nonferrous metal welding. Advanced Materials and Information Technology Processing; 2014/02/01: WIT Press; 2014.
    2. Praveen P, Yarlagadda PKDV. Meeting challenges in welding of aluminum alloys through pulse gas metal arc welding. Journal of Materials Processing Technology. 2005;164-165:1106-12.
    3. Pouraliakbar H, Hamedi M, Kokabi AH, Nazari A. Designing of CK45 carbon steel and AISI 304 stainless steel dissimilar welds. Materials Research. 2013;17(1):106-14.
    4. Paventhan R, Lakshminarayanan PR, Balasubramanian V. Fatigue behaviour of friction welded medium carbon steel and austenitic stainless steel dissimilar joints. Materials & Design. 2011;32(4):1888-94.
    5. Maurya AK, Pandey C, Chhibber R. Dissimilar welding of duplex stainless steel with Ni alloys: A review. International Journal of Pressure Vessels and Piping. 2021;192:104439.
    6. Reddy MP, William AAS, Prashanth MM, Kumar SNS, Ramkumar KD, Arivazhagan N, Narayanan S. Assessment of Mechanical Properties of AISI 4140 and AISI 316 Dissimilar Weldments. Procedia Engineering. 2014;75:29-33.
    7. Bystrianský V, Bystrianský J, Dumská K, Macák J, Návoj A. Effect of impurities in dissimilar metal welds on their corrosion behavior. Materials and Corrosion. 2021;72(8):1370-6.
    8. Soldering and brazing. Welding Processes Handbook: CRC Press; 2003.
    9. Abu-Aesh M, Taha M, Salem El–Sabbagh A, Dorn L. A Proposed Mechanism of Hot-Cracking Formation During Welding Fan-Shaped Test Specimen Using Pulsed-Current Gas Tungsten Arc Welding Process. Engineering and Applied Sciences. 2021;6(5):86.
    10. Wang Y, Tsutsumi S, Kawakubo T, Fujii H. Microstructure and mechanical properties of weathering mild steel joined by friction stir welding. Materials Science and Engineering: A. 2021;823:141715.
    11. Logan BP, Toumpis AI, Galloway AM, McPherson NA, Hambling SJ. Dissimilar friction stir welding of duplex stainless steel to low alloy structural steel. Science and Technology of Welding and Joining. 2016;21(1):11-9.
    12. Devaraj J, Ziout A, Abu Qudeiri JE. Dissimilar Non-Ferrous Metal Welding: An Insight on Experimental and Numerical Analysis. Metals. 2021;11(9):1486.
    13. Jafarzadegan M, Feng AH, Abdollah-zadeh A, Saeid T, Shen J, Assadi H. Microstructural characterization in dissimilar friction stir welding between 304 stainless steel and st37 steel. Materials Characterization. 2012;74:28-41.
    14. Jamshidi Aval H, Serajzadeh S, Kokabi AH, Loureiro A. Effect of tool geometry on mechanical and microstructural behaviours in dissimilar friction stir welding of AA 5086–AA 6061. Science and Technology of Welding and Joining. 2011;16(7):597-604.
    15. Kasai H, Morisada Y, Fujii H. Dissimilar FSW of immiscible materials: Steel/magnesium. Materials Science and Engineering: A. 2015;624:250-5.
    16. Aghaei A, Dehghani K. Characterizations of friction stir welding of dissimilar Monel400 and stainless steel 316. The International Journal of Advanced Manufacturing Technology. 2014;77(1-4):573-9.
    17. Karlsson L, Berqvist EL, Larsson H. Application of Friction Stir Welding to Dissimilar Welding. Welding in the World. 2002;46(1-2):10-4.
    18. Shen C, Zhang J, Ge J. Microstructures and electrochemical behaviors of the friction stir welding dissimilar weld. Journal of Environmental Sciences. 2011;23:S32-S5.
    19. Ishida K, Gao Y, Nagatsuka K, Takahashi M, Nakata K. Microstructures and mechanical properties of friction stir welded lap joints of commercially pure titanium and 304 stainless steel. Journal of Alloys and Compounds. 2015;630:172-7.
    20. DebRoy T, Bhadeshia HKDH. Friction stir welding of dissimilar alloys – a perspective. Science and Technology of Welding and Joining. 2010;15(4):266-70.
    21. Rodriguez J, Ramirez AJ. Friction stir welding of mild steel to alloy 625 – development of welding parameters. Science and Technology of Welding and Joining. 2014;19(4):343-9.
    22. Raj S, Biswas P. Mechanical and microstructural characterizations of friction stir welded dissimilar butt joints of Inconel 718 and AISI 204Cu austenitic stainless steel. Materials Characterization. 2022;185:111763.
    23. Sarkari Khorrami M, Saito N. On the formation of large grain structure after friction stir processing of ultrafine-grained aluminium alloy. Philosophical Magazine. 2023;103(8):733-48.
    24. Heidarzadeh A, Mironov S, Kaibyshev R, Çam G, Simar A, Gerlich A, et al. Friction stir welding/processing of metals and alloys: A comprehensive review on microstructural evolution. Progress in Materials Science. 2021;117:100752.
    25. Mirzadeh H. ‘Superplasticity of fine-grained austenitic stainless steels: A review’. Journal of Ultrafine Grained and Nanostructured Materials 2023, 56(1), 27-41.
    26. Liu X, Lan S, Ni J. Analysis of process parameters effects on friction stir welding of dissimilar aluminum alloy to advanced high strength steel. Materials & Design. 2014;59:50-62.
    27. Guo J, Gougeon P, Chen XG. Microstructure evolution and mechanical properties of dissimilar friction stir welded joints between AA1100-B4C MMC and AA6063 alloy. Materials Science and Engineering: A. 2012;553:149-56.
    28. Naghizadeh M, Mirzadeh H. Processing of fine grained AISI 304L austenitic stainless steel by cold rolling and high-temperature short-term annealing. Materials Research Express. 2018;5(5):056529.
    29. Liu FC, Hovanski Y, Miles MP, Sorensen CD, Nelson TW. A review of friction stir welding of steels: Tool, material flow, microstructure, and properties. Journal of Materials Science & Technology. 2018;34(1):39-57.
    30. Kumar J, Majumder S, Mondal AK, Verma RK. Influence of rotation speed, transverse speed, and pin length during underwater friction stir welding (UW-FSW) on aluminum AA6063: A novel criterion for parametric control. International Journal of Lightweight Materials and Manufacture. 2022;5(3):295-305.
    31. Meng X, Huang Y, Cao J, Shen J, dos Santos JF. Recent progress on control strategies for inherent issues in friction stir welding. Progress in Materials Science. 2021;115:100706.
    32. Yugandha K, Balaji PS, Chandu P, Prasanna RV, Magesh MN, Loganathan TG. A STUDY ON FSW PARAMETERS OF JOINING DISSIMILAR METALS - AL AND FE. International Journal Of Trendy Research In Engineering And Technology. 2022;06(01).
    33. Sejani D, Li W, Patel V. Stationary shoulder friction stir welding – low heat input joining technique: a review in comparison with conventional FSW and bobbin tool FSW. Critical Reviews in Solid State and Materials Sciences. 2021;47(6):865-914.
    34. Isa MSM, Moghadasi K, Ariffin MA, Raja S, Muhamad MRb, Yusof F, et al. Recent research progress in friction stir welding of aluminium and copper dissimilar joint: a review. Journal of Materials Research and Technology. 2021;15:2735-80.
    35. Saeid T, Abdollah-zadeh A, Shibayanagi T, Ikeuchi K, Assadi H. On the formation of grain structure during friction stir welding of duplex stainless steel. Materials Science and Engineering: A. 2010;527(24-25):6484-8.
    36. Emami S, Saeid T, Khosroshahi RA. Microstructural evolution of friction stir welded SAF 2205 duplex stainless steel. Journal of Alloys and Compounds. 2018;739:678-89.
    37. Nandan R, Debroy T, Bhadeshia H. Recent advances in friction-stir welding – Process, weldment structure and properties. Progress in Materials Science. 2008;53(6):980-1023.
    38. Lakshminarayanan AK, Balasubramanian V, Salahuddin M. Microstructure, Tensile and Impact Toughness Properties of Friction Stir Welded Mild Steel. Journal of Iron and Steel Research International. 2010;17(10):68-74.
    39. McPherson NA, Galloway AM, Cater SR, Hambling SJ. Friction stir welding of thin DH36 steel plate. Science and Technology of Welding and Joining. 2013;18(5):441-50.
    40. Shafiei-Zarghan A., Najafi A., Kashani-Bozorg S.F. and Zarei-Hanzaki A. ‘Effect of Zener-Hollomon Parameter on Microstructure of Aluminum Based Nanocomposite Layers Produced by Friction Stir Processing’. Journal of Ultrafine Grained and Nanostructured Materials 2021, 54(1), 29-39.
    41. Mondal M, Das H, Ahn EY, Hong ST, Kim M-J, Han HN, Pal TK. Characterization of friction stir welded joint of low nickel austenitic stainless steel and modified ferritic stainless steel. Metals and Materials International. 2017;23(5):948-57.
    42. Kumar SS, Murugan N, Ramachandran KK. Microstructure and mechanical properties of friction stir welded AISI 316L austenitic stainless steel joints. Journal of Materials Processing Technology. 2018;254:79-90.
    43. ahl sarmadi m, shamanian m, edris h, behjat a, atapoor m, Szpunar J, Mohtadi Bonab MA. Friction stir welding super duplex stainless steels UNS S32750 and evaluation of microstructure, mechanical and corrosion properties. Journal of Advanced Materials In Engineering. 2017;36(1):97-120.
    44. Sun Y, Fujii H. Improved resistance to hydrogen embrittlement of friction stir welded high carbon steel plates. International Journal of Hydrogen Energy. 2015;40(25):8219-29.
    45. Khodir SA, Morisada Y, Ueji R, Fujii H. Microstructures and mechanical properties evolution during friction stir welding of SK4 high carbon steel alloy. Materials Science and Engineering: A. 2012;558:572-8.
    46. Chung YD, Fujii H, Ueji R, Tsuji N. Friction stir welding of high carbon steel with excellent toughness and ductility. Scripta Materialia. 2010;63(2):223-6.
    47. Watanabe T, Takayama H, Yanagisawa A. Joining of aluminum alloy to steel by friction stir welding. Journal of Materials Processing Technology. 2006;178(1-3):342-9.
    48. Chung YD, Fujii H, Sun Y, Tanigawa H. Interface microstructure evolution of dissimilar friction stir butt welded F82H steel and SUS304. Materials Science and Engineering: A. 2011;528(18):5812-21.
    49. Bang H, Bang H, Jeon G, Oh I, Ro C. Gas tungsten arc welding assisted hybrid friction stir welding of dissimilar materials Al6061-T6 aluminum alloy and STS304 stainless steel. Materials & Design. 2012;37:48-55.
    50. A. Standard, “E3, Standard guide for preparation of metallographic specimens,” West Conshohecken, PA ASTM Int., 2017.

    ASTM E8 “Standard test method for tension testing of metallic materials” 2016.

    1. ASTM E8 “Standard test method for tension testing of metallic materials” 2016.
    2. Odnobokova M, Kipelova A, Belyakov A, Kaibyshev R. Microstructure evolution in a 316L stainless steel subjected to multidirectional forging and unidirectional bar rolling. IOP Conference Series: Materials Science and Engineering. 2014;63:012060.
    3. Arivazhagan N, Singh S, Prakash S, Reddy GM. An assessment of hardness, impact strength, and hot corrosion behaviour of friction-welded dissimilar weldments between AISI 4140 and AISI 304. The International Journal of Advanced Manufacturing Technology. 2007;39(7-8):679-89.