Abstract
In the present work, the dissimilar joints between C45 carbon steel and nickel-chromium 16NiCr6 steel rods were produced using rotary friction welding process. Statistical analysis based on response surface methodology (RSM), microstructural examination using scanning electron microscopy with backscattered electron diffraction (EBSD) and mechanical tests were performed to investigate the friction weld joints. The results showed that friction time and rotation speed were the most effective parameters on the weld joint quality with the highest t-ration of − 4.27, where the maximum bending strength of 1406.9 MPa was obtained at 2000 rpm for 13 s friction time. Increasing friction time to 13 s resulted in remarkable decrease in grain size (about 35%) at the weld interface, which increased the hardness (350HV0.1) and elastic modulus (260 GPa).Graphical abstract
Highlights
Welding is often the weak point of these joint structures, especially if they are subjected to shock or vibratory loads
Present study have found that the relationship between Ultimate bending strength (UBS) of the friction welded samples joints is a function of the friction welding parameters such as a Rotational speed (X1), friction pressure (X2) and Friction time (X3) which can be expressed as [24]: ultimate bending strength (UBS) = {X1;X2;X3}
Ferrite/pearlite ratio remained the same in both steels after welding, i.e., the proportion of ferrite is predominant in C45 and the rate of pearlite is higher in 16NiCr6
Summary
Welding is often the weak point of these joint structures, especially if they are subjected to shock or vibratory loads. Some of these dissimilar joints require the use of input metals, and relatively expensive and difficult welding techniques. Medium carbon steels have average or poor weld-ability, their very diverse use in the construction industry, due to their high mechanical strength. Rotary friction welding (RFW) allows similar and dissimilar joints to be produced, which is today a solution for obtaining high welded joints [5,6,7,8]. RFW used for production of vehicle parts such as drive shafts, engine valves, pumps and compressor [9]
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