Carbon Steel Joints Research Articles

Enhanced interfacial joining strength of joined high chromium gray cast iron/low carbon steel joint via graphite coating

Enhanced interfacial joining strength of joined high chromium gray cast iron/low carbon steel joint via graphite coating

Submerged arc welding process: enhancement of production performance based on metallurgical observations

Welding processes are widely used technologies in the industrial context for creating permanent connections between mechanical components. This popularity is due to their versatility, which arises from the numerous available process variants and the multiple advantages they offer compared to other joining techniques. In the manufacturing context, where devices often operate in extreme conditions, the quality of welds becomes a critical factor in ensuring the safety and reliability of the manufactured products. Furthermore, a sound joint requires careful compliance with the increasingly stringent design specifications demanded by customers who require industry-standard conformity in order to achieve defect-free, robust, and durable welds. To address these needs and to define the optimal roadmap for the investigated process condition, an experimental investigation was conducted on the submerged arc welding process. The experimental trials involved butt joints of ASTM A516 Gr.70 carbon steel plates with different thicknesses in a flat position, utilizing a U-shaped chamfer and a multi-pass welding technique. For each weldment, the effects of the main process parameters on the qualitative characteristics of the manufactured products were evaluated from a metallurgical perspective. This evaluation included an in-depth metallographic analysis of the heat-affected zone of the carbon steel joint and involved both the measurement of the dimensions of these areas as well as the amount of ferrite and pearlite that resulted as the phases observed in the final microstructure of the steel joint following its solidification. Furthermore, the joint quality was assessed with regard to mechanical strength through hardness measurements. By analysing the experimental data, the paper provides a valuable contribution for increasing the productivity of the investigated welding process, while simultaneously meeting the specified industrial quality requirements for the products made of medium-thickness carbon steels.

Joining of Al-Alloy Tubes by Carbon Steel Tubes using MPW Technique

Background/ Objectives: Joining aluminum alloys with low carbon steel (DC01) through fusion welding is a challenging task due to the occurrence of solidification defects like porosity, alloy segregation, and hot cracking. However, these issues can be addressed by employing solid-state welding techniques like explosive welding and MPW (magnetic pulse welding). MPW is a cost-effective and high-speed solid state welding method that involves creating joints in an overlap configuration. Methods: The MPW technique was employed to join dissimilar aluminum alloy AL 7075T6 hollow tube and DC01 steel rod in this study. A central composite design model was created to analyze the relationship between key MPW process parameters, including stand-off distance (SoD), overlap length, and discharge energy, and the bonding strength of the joints. Experimental setups were established and correlate with tensile-shear fracture load and interface hardness of the joints with the MPW process parameters. Findings: It is understood that the maximum TSFL of 2.404 kN was obtained under the welding condition of 23kJ discharge energy, 2.25 mm Stand-off distance, 8.5 mm overlap length, which is the optimum MP welding state for AA 7075 T6 with DC01 and confirmed by RSM. In addition, the cultivated connection can be aptly leveraged to anticipate the TSFL of MPW joints with a 95% confidence level. Novelty: The parametric mathematic samples were developed for forecasting TSFL of joints. The MPW parameters were optimized to enhance TSFL of joints. Aluminium alloys with low carbon steel joints were developed using MPW for cars and ships applications without fusion welding defects. Keywords: Magnetic Pulse Welding, Dissimilar Joint, (RSM) Response Surface Methodology, Tensile Shear-Fracture Load

Hydrogen Embrittlement Susceptibility of Linear Friction Welded Medium Carbon Steel Joints

Hydrogen Embrittlement Susceptibility of Linear Friction Welded Medium Carbon Steel Joints

Test on seismic behaviors of stainless steel bolted extended end-plate beam-column joints

This study conducted tests on the seismic behavior of austenitic stainless steel bolted extended end-plate beam-column joints, which have been few reported. Considering the influence of material type, end-plate thickness, bolt diameter, panel zone thickness, and loading scheme, 11 stainless steel joints and two carbon steel joints were designed and tested. Material properties, joint failure modes, moment-rotation curves, bolt load distributions, and joint component yield sequences were reported in detail. Experimental research showed that the beam-column joints in austenitic stainless steel experienced four failure modes, i.e. plastic hinge at the beam end, fracture failure of weld between the beam flange and end-plate, bolt rupture failure, and composite failure. All the tested joints had good seismic behavior, with rotation capacity greater than 0.03 rad. The influence of joint configurations on the seismic behavior were analyzed. The results indicated that the end-plate thickness, end-plate stiffener, and bolt diameter had a substantial impact on the joint seismic behavior, while the thickness of column web in panel zone, material properties, and loading scheme had a comparatively small effect. The initial rotational stiffness and moment resistance(yield moment) of joint obtained from the experiment were compared with the predictions of the EN1993-1-8, Design Guide 16, and JGJ 82-2011. Comparisons indicated that the EN1993-1-8 overestimated the initial rotational stiffness; Both the EN1993-1-8 and JGJ 82-2011 underestimated the moment resistance, while the predictions from the Design Guide 16 were significantly higher than the moment resistance and closer to the ultimate moment.

Tensile efficiency and fatigue life of similar and dissimilar carbon steel joints subjected to rotary friction welding

Rotary friction welding (RFW) is a solid-state welding method that can address the melting point limitation of other welding types; however, the welded area remains at risk of failure due to fatigue during operation. Fatigue failure is difficult to detect and predict, making it a critical failure mode in engineering. Although many fatigue life prediction methods are available, they do not consider the impact of RFW parameters (such as pressure, speed, and friction time) on fatigue strength. Owing to their good mechanical properties and commercial viability, carbon steel of grades C35 and C45 is commonly applied to manufacture main parts in the automotive industry. This study centers on employing RFW to join C35 and C45, representing the first-ever instance of using this technique to weld them together. The primary goal of RFW for C35 and C45 is to construct optimum parts that meet specific design requirements and have a long fatigue life. Findings showed C45–C45 joints (77 %) were more tensile-efficient than C35–C35 joints (73 %). Dissimilar C35–C45 joints reached 60 % of C45 base metal and 76 % of C35 base metal in terms of tensile efficiency. RFW welds had lower tensile strength than their base metals. Optimal results came at 35 MPa friction pressure and 8–12 s friction time for both similar and dissimilar RFW joints using the Coffin–Manson method, dissimilar C33–C45 joint fatigue life improved by over 85 %, aligning C35 and C45 engineering aspects. SEM microstructure analysis showed two regions: non-deformed (NDZ) and plastically deformed (PDZ), with broader PDZ indicating better tensile strength. These findings enhance RFW's efficiency, promoting automotive part longevity and safety.

Crack Growth Simulations With SMART Method in Adhesively Bonded Joints

Due to the important advantages of adhesive joints, such as their suitability for multi-material designs, their use has been increasing in the last decade. Determining the fracture behavior of structural adhesive bondings is essential for structural durability. In crack propagation analyses, adaptive meshing has drawn considerable attention because of its improvements in terms of complex preprocessing and time management. This paper presents a recently introduced separating morphing and adaptive remeshing technology (SMART) innovative crack growth simulation for adhesively bonded joints, considering static and cyclic cases. For the static case, an R-curve was obtained for the bonding joints of carbon steel and Araldite 2015. For the cyclic case, the Carbon Fiber Reinforced Polymer (CFRP) bonding joints were analyzed under constant-amplitude loading conditions. The crack-propagation rate and the number of cycles were estimated. Crack propagation simulations were validated using experimental data. Acceptable agreement was achieved between the experimental and estimated results.

Fatigue strength improvement of linear friction welded butt joints of low carbon steel by pressurizing after oscillation

Although linear friction welding (LFW) has received significant attention as an effective solid-state welding method, the fatigue properties of LFW joints have not been fully investigated. In this study, the fatigue strength of the steel joints fabricated using LFW was investigated and improved by increasing the pressure after oscillation. Low-carbon steel SM490A was successfully joined using LFW without unbonded areas or apparent softening in the heat-affected zone (HAZ). The microhardness, microstructure, weld toe shape, and fatigue life were assessed to investigate their relationships with the pressure conditions after oscillation. The results indicated that increasing the pressure after oscillation improved the area fraction of martensite (M) and the hardness of the weld interface center. The weld toe radius (ρ) and weld toe angle (α) also increased regardless of the upset control condition. The increasing of the pressure after oscillation from 50 MPa to 300 MPa increased ρ from 0.4 mm to 2.1 mm and the α increased from 92.7° to 103.4° at the weld center, accompanied by a reduced stress concentration factor (Kt) from 3.0 to 1.7. Under the fatigue test conditions of the stress range of 380 MPa, the fatigue life of the LFW as-welded joints was increased by approximately 31 % when the pressure after oscillation was 250 MPa compared to that of 50 MPa and by 87 % when it was 300 MPa compared to that of 250 MPa. Despite the possibility of fracture initiation at the weld toe at the edge of the LFW joints, the fatigue strength demonstrated a substantially longer fatigue life than the S-N design curve FAT90 recommended by the International Institute of Welding.

Effect of rotational speed on microstructure, mechanical property, and electrochemical behavior of friction stir welded joint of ultra-low carbon steel

Effect of rotational speed on microstructure, mechanical property, and electrochemical behavior of friction stir welded joint of ultra-low carbon steel

RETRACTED ARTICLE: Optimization of process variables for shielded metal arc welding dissimilar mild steel and medium carbon steel joints

We, the Editors and Publisher of the Journal of Adhesion Science and Technology , have retracted the following article: Vijayakumar, S., Arunkumar, A., Pradeep, A., Satishkumar, P., Singh, B., Rama Raju, K. S., & Sharma, V. K. (2024). Optimization of process variables for shielded metal arc welding dissimilar mild steel and medium carbon steel joints. Journal of Adhesion Science and Technology, 38(2), 185–202. https://doi.org/10.1080/01694243.2023.2227461 Since publication, a third party has raised concerns about the integrity of the data presented in the article and potential authorship concerns. When approached for an explanation, the authors have been unable to provide their original data to verify its authenticity. In addition, the authors have not fully responded to our questions regarding the process of the research conducted. As part of the investigation, we have been made aware of additional concerns regarding the inclusion of some authors on the author list, but the journal has been unable to verify these concerns, so the original author list is maintained. We have been informed in our decision-making by editorial policies and the COPE guidelines. The retracted article will remain online to maintain the scholarly record, but it will be digitally watermarked on each page as ‘Retracted’.

Effect of Heat Treatment on Crevice Corrosion Behavior of 304 Stainless Steel Clad Plate in Seawater Environment.

With the application of stainless steel clad plate (SSCP)-enlarging in the marine engineering field, awareness of the consequences of heat treatment on ameliorating microstructure and mechanical properties in stainless steel (SS)/carbon steel (CS) joints is being raised. However, carbide diffusion from a CS substrate to SS cladding may damage the corrosion resistance during inappropriate heating. In this paper, the corrosion behavior of a hot rolling-produced stainless steel clad plate (SSCP) after quenching and tempering (Q-T) treatment, especially crevice corrosion, was studied by electrochemical and morphological methods, such as cyclic potentiodynamic polarization (CPP), confocal laser scanning microscope (CLSM) and scanning electron microscopy (SEM). Q-T treatment led to more significance in carbon atoms diffusion and carbide precipitation, which made the passive film of the SS cladding surface on the SSCP unstable. Subsequently, a device for measuring the crevice corrosion performance of SS cladding was designed; the Q-T-treated cladding showed lower re-passivation potential (-585 mV) during CPP when compared to as-rolled (-522 mV), with the maximum corrosion depth ranging from 70.1 μm to 150.2 μm. In addition, the processing of crevice corrosion on SS cladding could be divided into three parts, including the initiation, propagation and development stages, which were driven by the interactions between corrosive media and carbides. The generation and growth mechanism of corrosive pits in crevices were revealed.

Tensile Strength and Microstructure of Rotary Friction-Welded Carbon Steel and Stainless Steel Joints

Due to the different properties of the materials, the fusion welding of dissimilar metals may be difficult. Structural irregularities may form as a result of various phase transformations during welding. Solid-state welding, as opposed to fusion welding, occurs below the melting temperature. As a result of the melting and solidification phenomena that happen in fusion welding, solid-state welding is expected to reduce the potential for phase transformation. This paper describes the use of a rotary friction welding technique to join carbon steel and 304 stainless steel. The purpose of this work is to investigate the characteristics of rotary friction welding (RFW) when joining 304 stainless steel to carbon steels with different carbon contents. Experiments were carried out on the RFW of low- and medium-carbon steels with 304 stainless steel. The investigation was carried out using the Taguchi method of experimental design. The joints’ tensile strengths and microstructures were evaluated. The parameters that had the greatest influence on the tensile strengths of the welding results were identified. The combination of parameters resulting in the greatest tensile strength is also suggested. A microstructural examination of the weldment revealed mechanical mixing and interlocking.

Thermo-Mechanical Analysis of Girth Welding Process on Flange Pipe Joints using Moving Heat Source Extension

This paper forecasts the transient thermal temperature history during girth welding with a single pass over the welded area on pipe ASME class 300 flange joints of low carbon steel using the moving heat source extension model. Using ANSYS ACT extension for the model of the moving, heat source is simulated for the forecast of the distribution of temperature over the welded region during the welding process like gas metal arc welding. Then due to the residual stress induced by the thermal load of the welding, heat source on the joints is analysed and then comparison of the various heat distribution by changing welding parameters is analysed for optimal welding parameters to reduce the stress. The analysis was carried out on transient thermal and transient structural processes to predict the temperature distribution and residual stress respectively.

Parametric mathematical modeling and 3D response surface analysis for rod to plate friction welding of AISI 1020 steel/AISI 1018 steel

PurposeRotary friction welding (RFW) was used to solve the issues in fusion welding of rod to plate joints of low carbon steel (AISI 1020 steel/AISI 1018 steel) such solidification cracking, wider heat affected zone (HAZ), lower HAZ hardness, high residual stresses and distortion. The main objective of this investigation is to develop parametric mathematic models (PMMs), 3D response surface analysis to predict tensile strength (TS) and weld interface hardness (WIH) of rod to plate joints and correlate microstructure with TS and WIH of rod to plate joints.Design/methodology/approachThe three-factor x five-level central composite design (CCD) consisting fewer experiments was employed for designing experimental matrix. The tensile and microhardness tests were performed to evaluate mechanical performance of joints. The PMMs of TS and WIH of rod to plate joints were developed using polynomial regression equations incorporating the RFW parameters. The 3D response surfaces were developed using response surface methodology (RSM) to optimize RFW parameters for joining AISI 1020/AISI 1018 rod to plate.FindingsThe joints made using friction pressure/friction time (FRNP/FRNT) of 3.71 MPa/s, forging pressure/forging time (FRGP/FRGT) of 3.71 MPa/s and rotational speed (RTSP) of 19.99 rps exhibited higher TS and WIH of 452 MPa and 252 HV0.5. The PMMs accurately predicted TS and WIH of rod to plate joints at less than 1.5% error and 95% confidence. The RTSP revealed greater effect on TS and WIH of rod to plate joints followed by FRGP/FRGT and FRNP/FRNT. The superior TS and WIH of joints developed using optimized process parameters is correlated to the evolution of finer bainitic microstructure in weld interface due to the dynamic recrystallization of grains ensued by optimum frictional heating and plastic deformation.Originality/valueThe PMMs were developed for predicting TS and WIH of joints. The RFW parameters were optimized to enhance TS and WIH of joints. Low carbon steel rod to plates joints were developed using RFW for automotive applications without fusion welding defects. The microstructural features of low strength and high strength rod to plate joints were correlated to the TS and WIH of rod to plate joints.

Effects of Preheating on Microstructural and Mechanical Properties of Friction Stir Welded Thin Low Carbon Steel Joints

Abstract Friction stir welding of a low carbon thin steel plate was performed with preheating the base material to increase the joining performance. The rotational speed of the tool was set from 1500 to 2000 rpm with a constant travel speed of 15 mm/min and preheating temperature of 50 to 150 °C. The tensile strength of 340 MPa was achieved for the preheated specimen compared with 310 MPa for the non-preheating specimen at the welding speed of 15 mm/min. Electron microscopic images of the preheated joint revealed a remarkable plasticized material flow and dynamic recrystallization, which resulted in the grain refinement that had increased the joining strength. The weld thinning issue was almost eliminated in the preheated welded specimen. However, by increasing the preheat temperature further, the tensile strength decreases due to the formation of defects from excessive heat. The preheated sample fractured at the base metal, revealing a ductile fracture mode.

Fatigue behaviour and impact strength assessment of friction stir-welded carbon steel joints

The present study investigates the fatigue behaviour and impact strength of friction stir-welded (FSWed) carbon steel (AISI 1018) joints in comparison with the base metal (BM). The fatigue behaviour was tested using compact tension (CT) specimen of BM and FSWed joints under the constant amplitude load at different values of stress ratio (R) having a frequency of 10 Hz. A 20% increase in fatigue life along with a lower fatigue crack propagation rate was observed for FSWed specimens when compared to BM. The impact strength of BM and FSWed specimens was measured using the Charpy test. A higher value of impact strength was observed in FSWed specimens in comparison to BM. Additionally, regression analysis was carried out to model impact energy in terms of input parameters. Microstructural examination of a fractured surface of the FSWed specimen revealed the ductile fracture. A higher microhardness value was also observed in FSWed specimens when compared to BM.

Improving the Tensile Strength Between Pure Al and Low Carbon Steel Joint Fabricated by Friction Welding

Improving the Tensile Strength Between Pure Al and Low Carbon Steel Joint Fabricated by Friction Welding

Studying the strengthening mechanisms and mechanical properties of dissimilar laser-welded butt joints of medium-Mn stainless steel and automotive high-strength carbon steel

In this study, a post-weld heat treatment (PWHT) at a high temperature of 700 °C for 10 min was proposed to significantly improve the mechanical performance of dissimilar laser-welded butt joints between medium-manganese stainless steel (MMn-SS) and high-strength carbon steels (HS-CS) as base metals (BMs). Electron backscatter diffraction and transmission electron microscopy were employed to characterise the microstructures and study the deformation mechanisms in the paired metals of the dissimilar joints during PWHT and tensile straining. Micro-indentation hardness tests were performed to analyse the mechanical responses in the weld zones after PWHT. The results revealed that PWHT at 700 °C significantly affected the microstructure and mechanical strength of the BMs and their weldments. A fully tempered martensitic microstructure with recrystallised grain regions was formed in the fusion zones (FZs) of the weldments, which were processed at low and high specific point energies (SPEs) of 19, 25, and 30 J. BM HS-CS was significantly strengthened owing to the interphase precipitation hardening of vanadium carbide precipitates during the proposed PWHT. The strength-ductility balance of BM MMn-SS was improved by combining the martensitic transformation and mechanical twinning mechanisms. Although, the tensile strength of BM HS-CS increased from 500 to 630 MPa and that of the metal in the FZ decreased from 1100 to 800 MPa owing to PWHT. Hence, HS-CS is a weak metal for dissimilar joints, and joint failure was promoted in it.

Microstructure and shearing strength of stainless steel/low carbon steel joints produced by resistance spot welding

The present research utilized the resistance spot welding process on stainless steel and low carbon steel. The diameters of joint and nugget, microstructure and shearing strength of joints were examined. When increasing the welding current, welding time or clamping force, the diameters of welding joints and nuggets became larger due to the higher heat input and normal load. The shearing strength of joints increased and then decreased with increasing welding current or welding time and decreased with increasing clamping force. For the metallurgical evaluation, it was found that there were five regions around the joint, which consisted of the nugget (austenite and martensite with dendritic structures), coarse heat-affected zone (martensite and pro-eutectoid ferrite), fine heat-affected zone (ferrite and pearlite), base material (ferrite and pearlite) for low carbon steel, and base material (austenite) for stainless steel. In orthogonal tests, it was found that the welding current had the most significant influences on shearing strength, and then welding time and clamping force. Finally, an artificial neural network was established to predict the shearing strength of joints under various welding conditions. The results showed that the shearing strengths predicted by the artificial neural network had good correlation with experimental values. A shearing strength higher than 10000 N could be achieved when welding current was higher than 12.5 kA and welding time was longer than 85 ms. The artificial neural network model has applicable values for predicting the shearing strengths of joints between dissimilar steel plates.

Electrochemical behavior of friction stir welded joint of ultra-low carbon steel

In this study, friction stir welding of ultra low carbon steel was performed at tool rotational speeds in the range from 300 to 750rpm with 150rpm increments at 60mm/min fixed traverse speed. Throughout study was performed on macro and micro structures in order to determine the several welded zones for example stir zone, thermo-mechanically affected zone, and heat-affected zone. Microhardness profiles were performed along the welded joint's cross section and the utmost hardness was obtained at stir or nugget zone as compared to the other zones of the welded joints. The hardness values on the stir zone decreases with rise in tool rotating speed. Electrochemical study was investigated in 3.5%NaCl electrolyte solution. Corrosion rate is maximum (~27MPY) at 300 rpm stir zone and minimum value (~0.3 MPY) obtained at heat affected zone at 750rpm welded sample.