Abstract
This paper presents an effect of friction welding parameters on the tensile strength and microstructural properties of dissimilar AISI 1020-ASTM A536 joints. A hybrid response surface methodology (RSM) and genetic algorithm (GA)-based technique were successfully developed to model, simulate, and optimise the welding parameters. Direct and interaction effects of process parameters on the ultimate tensile strength (UTS) were studied by plotting graphs. Friction force and friction time have a positive effect on tensile strength. As friction force and friction time increase, the tensile strength also increases. The maximum tensile strength of the friction-welded low carbon steel-ductile iron joints was 87 % of that of the base metal. The tensile properties, microstructure, Vickers hardness distribution, and fracture morphology of the welded specimen have been studied and presented in this study. Additionally, the distribution of carbon element on both sides of the interface was estimated using energy-dispersive spectroscopy (EDS). The results of the metallographic study show clearly that the friction welding process was accompanied by a diffusion of carbon atoms from ductile iron to steel. This process causes the formation of a carbon-rich zone at the interface and decarburization zone in the ductile iron close to the bond interface.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Davis JR (1996) ASM speciality handbook: cast irons. ASM International, Metals Park, OH, USA
Handbook W (1991) Welding process, vol 2, 8th-ed. AWS, Miami
Handbook ASM (1992) Metallography and microstructures, vol 9. ASM International, Metals Park, OH, USA
Handbook ASM (1995) Properties and selection iron and steel, vol 1. ASM International, Materials Park, OH, USA
Pascual M, Cembrero J, Salas F (2008) Analysis of the weldability of ductile iron. Mater Lett 62:1359–1362
Klimpel A (1998) The problem of welding cast irons is examined taking the example of a spheroidal cast iron. Weld Int 12(1):20–24
El-Banna EM (1999) Effect of preheat on welding of ductile cast iron. Mater Lett 41:20–26
Crossland B (1971) Friction welding. Contemp Phys 12(6):559–574
American Welding Society (1989) Specifications and standards. In: Recommended practice for friction welding, AWS, Miami
Lebedev VK, Chernenko IA (1992) Welding and surface reviews friction welding. Harwood Academic Publishers, Amsterdam
Mitelea I, Craciunescu CM, Gugu R (2010) Interfacial behavior of dissimilar friction welded nodular cast irons with low carbon steels. Mater Sci For 638–642:3757–3762
Richter H, Palzkill A (1985) Applicability of test result from miniature friction welded specimens to full-size specimens as demonstrated by the combination of constructional steel and spheroidal graphite cast iron. Weld Cutt 37:60–5
Dette M, Hirsch J (1990) Reibschweissen von Konstruieren aus Kugelgraphitguss mit Stahlteilen. Schw und Schn 11(42):188–190
Michiura Y, Maekawa K, Takahara W, Kitagawa M, Horie H (1998) Friction welding of ductile cast iron pipes. Jpn J Foundry Eng Soc 70:873–877
Shinoda T, Endo S, Kato Y (1999) Friction welding of cast iron and stainless steels. Weld Int 13(2):89–95
Ochi H, Kawai G, Morikawa K, Yamamoto Y, Suga Y (2007) Macrostructure and temperature distribution near the weld interface in friction welding of cast iron. Strength Fract Compl 5:79–88
Song Y, Liu Y, Zhu X, Yu S, Zhang Y (2008) Strength distribution at interface of rotary-friction-welded aluminium to nodular cast iron. Trans Nonf Met Soc China 18:14–18
Winiczenko R, Kaczorowski M (2012) Friction welding of ductile cast iron using interlayers. Mater Des 34:444–451
Winiczenko R, Kaczorowski M (2013) Friction welding of ductile iron with stainless steel. J Mater Process Technol 213:453–462
Handbook ASM (2010) Metals process simulation, vol 22b. ASM International, Materials Park, OH, USA
Deb K (1998) Optimization for engineering design. Prentice-Hall, New Delhi
Montgomery DC (2009) Design and analysis of experiments, 7-edth edn. Wiley, New York
ASTM E8 M-04 (2010) Standard test methods for tension testing of metallic materials. ASTM International
Design-Expert Software (2009) Version 8.0 user’s guide
Murti KG, Sundaresan S (1983) Parameter optimization in friction welding dissimilar materials. Met Construct 331–335
Canyurt O (2005) Estimation of welded joint strength using genetic algorithm approach. Int J of Mech Sci 47:1249–1261
Paventhan R, Lakshminarayanan PR, Balasubramanian V (2011) Prediction and optimization of friction welding parameters for joining aluminium alloy and stainless steel. Trans Nonf Met Soc China 21:1480–148
Sathiya P (2009) Optimization of friction welding parameters using evolutionary computational techniques. J Mater Process Technol 5:2576–2584
Kumaran SS, Muthukumaran S, Vinodh S (2010) Optimization of friction welding of tube to tube plate using an external tool. Struct Multidisc Optim 42(3):449–457
Kumaran SS, Muthukumaran S, Vinodh S (2011) Optimization of friction welding of tube-to-tube plate using an external tool by Taguchi method and genetic algorithm. Int J Adv Manuf Technolo 57:167–182
Dey V, Pratihar DK, Datta GL, Jha MN, Saha TK, Bapat AV (2009) Optimization of bead geometry in electron beam welding using a genetic algorithm. J Mater Process Technol 209:1151–7
Padmanaban G, Balasubramanian V (2010) Prediction of tensile strength and optimization of process parameters for friction stir welded AZ31B magnesium. Proceed Inst Mech Eng, Part B: J of Eng Manuf 10(224):1519–1528
Babu S, Elangovan K, Balasubramanian V, Balasubramanian M (2009) Optimizing friction stir welding parameters to maximize tensile strength of AA2219 aluminum alloy joints. Met Mater Int 15:321–330
Bilgin MB, Meran C, Canyurt OE (2013) Optimization of strength of friction welded joints for AISI 430 ferritic stainless steels by genetic algorithm. Int J Adv Manuf Technolo 73:doi 10.1007/s00170-014-6590-0
Elangovan S, Anand K, Prakasan K (2012) Parametric optimization of ultrasonic metal welding using response surface methodology and genetic algorithm. Int J Adv Manuf Technolo 63:561–572
Winiczenko R, Sałat R, Awtoniuk M (2013) Estimation of tensile strength of ductile iron friction welded joints using hybrid intelligent methods. Trans Nonf Met Soc China 23(2):385–391
Udayakumar T, Raja K, Afsal Husain TM, Sathiya P (2014) Prediction and optimization of friction welding parameters for super duplex stainless steel (UNS S32760) joints. Mater Des 53:226–235
Deb K (2001) Multi-objective optimization using evolutionary algorithms. John Wiley and Sons, Ltd., England
Gen M, Cheng R (2000) Genetic algorithm and engineering optimization. John Wiley & Sons, Inc.
Goldberg DE (1989) Genetic algorithm in search, optimization and machine learning. Addison-Wesley, Reading
Ellis CRG (1972) Continuous direct drive friction welding of mild steel. Weld Res Suppl 4:183–197
Kurt A, Uygur I, Paylasan U (2011) Effect of friction welding parameters on mechanical and microstructural properties of dissimilar AISI 1010-ASTM B22 joints. Weld J 90:102–106
Winiczenko R, Kaczorowski M (2015) Friction welding of ductile irons. In: Colás R and Totten GE (ed) Encyclopedia of iron, steel, and their alloys, 1st edn. Francis & Taylor Group, New York (accepted)
Sahin M (2009) Joining of stainless-steel and aluminium materials by friction welding. Int J Adv Manuf Technolo 41:487–497
Sahin M (2010) Joining of aluminium and copper materials with friction welding. Int J Adv Manuf Technol 49:527–534
Cheng CP, Lin HM, Lin JC (2010) Friction welding of ductile iron and low carbon steel. Sci Technol Weld Join 15(8):706–711
Fujii H, Cuia L, Tsuji N, Maeda M, Nakata K, Nogi K (2006) Friction stir welding of carbon steels. Mater Sci Eng A 429(1–2), 15:50–57
Nguyen TC, Weckman DC (2006) A thermal and microstructure evolution model of direct-drive friction welding of plain carbon steel. Metall and Mater Trans B 37(2):275–292
Sathiya P, Aravindan S, Noorul Haq A (2007) Effect of friction welding parameters on mechanical and metallurgical properties of ferritic stainless steel. Int J Adv Manuf Technol 31:1076–1082
Chang HT, Wang CJ, Cheng CP (2014) Microstructure feature of friction stir butt-welded ferritic ductile iron. Mater Des 56:572–578
Baker H (1990) Alloy phase diagram, vol 3. ASM Handbook, Materials Park, Ohio
Shamanian M, Mousavi Abarghouie SMR, Mousavi Pour SR (2010) Effects of surface alloying on microstructure and wear behavior of ductile iron. Mater Des 31:2760–2766
Benyounis KY, Fakron OMA, Abboud JH, Olabi AG, Hashmi MJS (2005) Surface melting of nodular cast iron by Nd-YAG laser and TIG. J Mater Process Technol 170:127–13220
Pouranvar M (2010) On the weldability of grey cast iron using nickel based filler metal. Mater Des 31(7):3253–3258
Calvo FA, Urena A, Gomez de Salzar JM, Molleda F (1989) Diffusion bonding of grey cast iron to Armco iron and a carbon steel. J Mater Sci 24(11):4152–4159
Dieter GE (1986) Mechanical metallurgy. McGraw-Hill Co., New York
Askari-Paykani M, Shayan M, Shamanian M (2014) Weldability of ferritic ductile cast iron using full factorial design of experiment. J Iron Steel Res Int 21(2):252–263
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.
About this article
Cite this article
Winiczenko, R. Effect of friction welding parameters on the tensile strength and microstructural properties of dissimilar AISI 1020-ASTM A536 joints. Int J Adv Manuf Technol 84, 941–955 (2016). https://doi.org/10.1007/s00170-015-7751-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-015-7751-5