The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding

Friction welding is a solid state joining process used extensively currently owing to its advantages such as low heat input, high production efficiency, ease of manufacture, and environment friendliness. Materials difficult to be welded by fusion welding processes can be successfully welded by frict...

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Дата:2015
Автори: Caligulu, U., Yalcinoz, M., Kati, N., Balalan, Z., Islak, S.
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Мова:English
Опубліковано: Інститут металофізики ім. Г.В. Курдюмова НАН України 2015
Назва видання:Металлофизика и новейшие технологии
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Онлайн доступ:https://nasplib.isofts.kiev.ua/handle/123456789/112021
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Цитувати:The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding / U. Caligulu, M. Yalcinoz, N. Kati, Z. Balalan, S. Islak // Металлофизика и новейшие технологии. — 2015. — Т. 37, № 5. — С. 665-681. — Бібліогр.: 33 назв. — англ.

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spelling nasplib_isofts_kiev_ua-123456789-1120212025-02-09T09:58:57Z The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding Вплиав швидкості обертання і часу тертя на з’єднання сталей AISI 4340—2205 зварюванням тертям Влияние скорости вращения и времени трения на соединение сталей AISI 4340—2205 сваркой трением Caligulu, U. Yalcinoz, M. Kati, N. Balalan, Z. Islak, S. Физика прочности и пластичности Friction welding is a solid state joining process used extensively currently owing to its advantages such as low heat input, high production efficiency, ease of manufacture, and environment friendliness. Materials difficult to be welded by fusion welding processes can be successfully welded by friction welding. In the fusion welding methods for joining different materials, brittle intermetallic compounds phases are produced in the fusion zone, which reduces the strength of the welding joint. In this study, the effects of rotation speed and friction time for joining of AISI 4340—2205 steels welded by friction are investigated. Specimens of AISI 4340 tempered steel and AISI 2205 duplex stainless steel, each of 12 mm diameters, are used to fabricate the joints. The friction welding tests are carried out using a direct-drive type friction-welding machine, which was designed and manufactured for this purpose by us. After friction welding, in order to determine the occurred microstructural changes, the interface regions of the welded specimens are examined by means of OM, SEM, EDS and X-Ray analysis. Microhardness and tensile tests are conducted to determine the mechanical properties of the welded specimens. The experimental results indicate that AISI 4340 tempered steel could be joined to AISI 2205 duplex stainless steel using the friction welding technique and for achieving a weld with sufficient strength. Tensile strength values also confirm this result, and, at the interface, intermetallic phases do not occurred. The maximum tensile strength of 635.66 MPa could be obtained for the joints welded under the welding conditions of rotation speed of 2200 rpm, friction pressure of 40 MPa, forging pressure of 80 MPa, friction time of 6 s, and forging time of 3 s. Зварювання тертям являє собою процес твердотільного з’єднання, який в теперішній час інтенсивно використовується завдяки таким його перевагам, як низька підвідна теплота, висока продуктивність, простота реалізації та дружність до довкілля. Матеріяли, які важко з’єднуються зварюванням топленням, можуть бути успішно зварені зварюванням тертям. Методи зварювання топленням при з’єднанні різних матеріялів характеризуються утворенням в зоні стоплення фаз крихких інтерметалевих з’єднань, які знижують міцність зварного з’єднання. В даній роботі досліджується вплив швидкости обертання та часу тертя на з’єднання тертям сталей AISI 4340—2205. Зразки з відгартованої сталі AISI 4340 і двофазної неіржавійної сталі AISI 2205, кожний діяметром у 12 мм, використовувалися для виготовлення з’єднань. Випробування зварювання тертям виконувалися з використанням машини для зварювання тертям безредукторного типу, яку було сконструйовано та виготовлено нами для цього. Після зварювання тертям для визначення мікроструктурних змін в області роздільчої межі зварених зразків використовувалися методи оптичної та сканувальної електронної мікроскопії, а також енергодисперсійна рентґенівська спектроскопія та рентґенодифракційний аналіз. Для визначення механічних властивостей зварених зразків виконувалися дослідження мікротвердости та випробування на розрив. Результати експериментів показують, що відгартована сталь AISI 4340 може з’єднуватися з двофазною неіржавійною сталлю AISI 2205 методою зварювання тертям з одержанням зварного шва достатньої міцности. Значення міцности на розрив також підтвердили цей результат і те, що в області контакту не виникають інтерметалеві фази. Максимальної міцности на розрив у 635,66 МПа було досягнуто для з’єднань, яких було одержано за наступних умов зварювання: швидкість обертання – 2200 об/хв., тиск тертя – 40 МПа, тиск пресування – 80 МПа, час тертя – 6 с, а час пресування – 3 с. Сварка трением является процессом твердотельного соединения, который в настоящее время интенсивно используется благодаря таким его преимуществам, как низкая подводимая теплота, высокая производительность, простота реализации и дружественность по отношению к окружающей среде. Материалы, которые трудно соединяются сваркой плавлением, могут быть успешно сварены сваркой трением. Методы сварки плавлением при соединении различных материалов характеризуются образованием в зоне сплавления фаз хрупких интерметаллических соединений, которые снижают прочность сварного соединения. В настоящей работе исследуется влияние скорости вращения и времени трения на соединение трением сталей AISI 4340—2205. Образцы из отпущенной стали AISI 4340 и двухфазной нержавеющей стали AISI 2205, каждый диаметром 12 мм, использовались для изготовления соединений. Испытания сварки трением производились с использованием машины для сварки трением безредукторного типа, которая была сконструирована и изготовлена нами для этой цели. После сварки трением для определения микроструктурных изменений в области границы раздела сваренных образцов использовались методы оптической и сканирующей электронной микроскопии, а также энергодисперсионная рентгеновская спектроскопия и рентгенодифракционный анализ. Для определения механических свойств сваренных образцов проводились исследования микротвёрдости и испытания на разрыв. Результаты экспериментов показывают, что отпущенная сталь AISI 4340 может соединяться с двухфазной нержавеющей сталью AISI 2205 методом сварки трением с получением сварного шва достаточной прочности. Значения прочности на разрыв также подтвердили этот результат и то, что в области контакта не образуются интерметаллические фазы. Максимальная прочность на разрыв 635,66 МПа была достигнута для соединений, полученных при следующих условиях сварки: скорость вращения – 2200 об/мин., давление трения – 40 МПа, давление прессования – 80 МПа, время трения – 6 с и время прессования – 3 с. 2015 Article The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding / U. Caligulu, M. Yalcinoz, N. Kati, Z. Balalan, S. Islak // Металлофизика и новейшие технологии. — 2015. — Т. 37, № 5. — С. 665-681. — Бібліогр.: 33 назв. — англ. 1024-1809 PACS: 06.60.Vz, 62.20.Qp, 81.20.Vj, 81.40.Pq, 81.70.Bt, 81.70.Jb, 83.50.Uv https://nasplib.isofts.kiev.ua/handle/123456789/112021 en Металлофизика и новейшие технологии application/pdf Інститут металофізики ім. Г.В. Курдюмова НАН України
institution Digital Library of Periodicals of National Academy of Sciences of Ukraine
collection DSpace DC
language English
topic Физика прочности и пластичности
Физика прочности и пластичности
spellingShingle Физика прочности и пластичности
Физика прочности и пластичности
Caligulu, U.
Yalcinoz, M.
Kati, N.
Balalan, Z.
Islak, S.
The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding
Металлофизика и новейшие технологии
description Friction welding is a solid state joining process used extensively currently owing to its advantages such as low heat input, high production efficiency, ease of manufacture, and environment friendliness. Materials difficult to be welded by fusion welding processes can be successfully welded by friction welding. In the fusion welding methods for joining different materials, brittle intermetallic compounds phases are produced in the fusion zone, which reduces the strength of the welding joint. In this study, the effects of rotation speed and friction time for joining of AISI 4340—2205 steels welded by friction are investigated. Specimens of AISI 4340 tempered steel and AISI 2205 duplex stainless steel, each of 12 mm diameters, are used to fabricate the joints. The friction welding tests are carried out using a direct-drive type friction-welding machine, which was designed and manufactured for this purpose by us. After friction welding, in order to determine the occurred microstructural changes, the interface regions of the welded specimens are examined by means of OM, SEM, EDS and X-Ray analysis. Microhardness and tensile tests are conducted to determine the mechanical properties of the welded specimens. The experimental results indicate that AISI 4340 tempered steel could be joined to AISI 2205 duplex stainless steel using the friction welding technique and for achieving a weld with sufficient strength. Tensile strength values also confirm this result, and, at the interface, intermetallic phases do not occurred. The maximum tensile strength of 635.66 MPa could be obtained for the joints welded under the welding conditions of rotation speed of 2200 rpm, friction pressure of 40 MPa, forging pressure of 80 MPa, friction time of 6 s, and forging time of 3 s.
format Article
author Caligulu, U.
Yalcinoz, M.
Kati, N.
Balalan, Z.
Islak, S.
author_facet Caligulu, U.
Yalcinoz, M.
Kati, N.
Balalan, Z.
Islak, S.
author_sort Caligulu, U.
title The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding
title_short The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding
title_full The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding
title_fullStr The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding
title_full_unstemmed The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding
title_sort effects of rotation speed and friction time for joining of aisi 4340—2205 steels by friction welding
publisher Інститут металофізики ім. Г.В. Курдюмова НАН України
publishDate 2015
topic_facet Физика прочности и пластичности
url https://nasplib.isofts.kiev.ua/handle/123456789/112021
citation_txt The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding / U. Caligulu, M. Yalcinoz, N. Kati, Z. Balalan, S. Islak // Металлофизика и новейшие технологии. — 2015. — Т. 37, № 5. — С. 665-681. — Бібліогр.: 33 назв. — англ.
series Металлофизика и новейшие технологии
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fulltext 665 PACS numbers:06.60.Vz, 62.20.Qp,81.20.Vj,81.40.Pq,81.70.Bt,81.70.Jb, 83.50.Uv The Effects of Rotation Speed and Friction Time for Joining of AISI 4340—2205 Steels by Friction Welding U. Caligulu, M. Yalcinoz*, N. Kati*, Z. Balalan**, and S. Islak *** Firat University, Faculty of Technology, Department of Met. and Materials Eng., 23119 Elazig, Turkey *Firat University, Faculty of Technical Education, Dept. of Metallurgy Education, 23119 Elazig, Turkey **Bingol University, Faculty of Engineering, Department of Met. and Materials Eng., 12000 Bingol, Turkey ***Kastamonu University, Faculty of Eng. and Arch., Dept. of Mat. Sci. and Nanotech. Eng., Kastamonu, Turkey Friction welding is a solid state joining process used extensively currently owing to its advantages such as low heat input, high production efficiency, ease of manufacture, and environment friendliness. Materials difficult to be welded by fusion welding processes can be successfully welded by friction welding. In the fusion welding methods for joining different materials, brit- tle intermetallic compounds phases are produced in the fusion zone, which reduces the strength of the welding joint. In this study, the effects of rota- tion speed and friction time for joining of AISI 4340—2205 steels welded by friction are investigated. Specimens of AISI 4340 tempered steel and AISI 2205 duplex stainless steel, each of 12 mm diameters, are used to fabricate the joints. The friction welding tests are carried out using a direct-drive type friction-welding machine, which was designed and manufactured for this purpose by us. After friction welding, in order to determine the occurred mi- crostructural changes, the interface regions of the welded specimens are ex- amined by means of OM, SEM, EDS and X-Ray analysis. Microhardness and tensile tests are conducted to determine the mechanical properties of the welded specimens. The experimental results indicate that AISI 4340 tem- pered steel could be joined to AISI 2205 duplex stainless steel using the fric- tion welding technique and for achieving a weld with sufficient strength. Металлофиз. новейшие технол. / Metallofiz. Noveishie Tekhnol. 2015, т. 37, № 5, сс. 665—681 Оттиски доступны непосредственно от издателя Фотокопирование разрешено только в соответствии с лицензией 2015 ИМФ (Институт металлофизики им. Г. В. Курдюмова НАН Украины) Напечатано в Украине. 666 U. CALIGULU, M. YALCINOZ, N. KATI et al. Tensile strength values also confirm this result, and, at the interface, inter- metallic phases do not occurred. The maximum tensile strength of 635.66 MPa could be obtained for the joints welded under the welding condi- tions of rotation speed of 2200 rpm, friction pressure of 40 MPa, forging pressure of 80 MPa, friction time of 6 s, and forging time of 3 s. Зварювання тертям являє собою процес твердотільного з’єднання, який в теперішній час інтенсивно використовується завдяки таким його перева- гам, як низька підвідна теплота, висока продуктивність, простота реалі- зації та дружність до довкілля. Матеріяли, які важко з’єднуються зварю- ванням топленням, можуть бути успішно зварені зварюванням тертям. Методи зварювання топленням при з’єднанні різних матеріялів характе- ризуються утворенням в зоні стоплення фаз крихких інтерметалевих з’єднань, які знижують міцність зварного з’єднання. В даній роботі дос- ліджується вплив швидкости обертання та часу тертя на з’єднання тертям сталей AISI 4340—2205. Зразки з відгартованої сталі AISI 4340 і двофазної неіржавійної сталі AISI 2205, кожний діяметром у 12 мм, використовува- лися для виготовлення з’єднань. Випробування зварювання тертям вико- нувалися з використанням машини для зварювання тертям безредуктор- ного типу, яку було сконструйовано та виготовлено нами для цього. Після зварювання тертям для визначення мікроструктурних змін в області роз- дільчої межі зварених зразків використовувалися методи оптичної та сканувальної електронної мікроскопії, а також енергодисперсійна рент- ґенівська спектроскопія та рентґенодифракційний аналіз. Для визначен- ня механічних властивостей зварених зразків виконувалися дослідження мікротвердости та випробування на розрив. Результати експериментів показують, що відгартована сталь AISI 4340 може з’єднуватися з двофаз- ною неіржавійною сталлю AISI 2205 методою зварювання тертям з одер- жанням зварного шва достатньої міцности. Значення міцности на розрив також підтвердили цей результат і те, що в області контакту не виника- ють інтерметалеві фази. Максимальної міцности на розрив у 635,66 МПа було досягнуто для з’єднань, яких було одержано за наступних умов зва- рювання: швидкість обертання – 2200 об/хв., тиск тертя – 40 МПа, тиск пресування – 80 МПа, час тертя – 6 с, а час пресування – 3 с. Сварка трением является процессом твердотельного соединения, который в настоящее время интенсивно используется благодаря таким его пре- имуществам, как низкая подводимая теплота, высокая производитель- ность, простота реализации и дружественность по отношению к окружа- ющей среде. Материалы, которые трудно соединяются сваркой плавлени- ем, могут быть успешно сварены сваркой трением. Методы сварки плав- лением при соединении различных материалов характеризуются образо- ванием в зоне сплавления фаз хрупких интерметаллических соединений, которые снижают прочность сварного соединения. В настоящей работе исследуется влияние скорости вращения и времени трения на соединение трением сталей AISI 4340—2205. Образцы из отпущенной стали AISI 4340 и двухфазной нержавеющей стали AISI 2205, каждый диаметром 12 мм, использовались для изготовления соединений. Испытания сварки трени- ем производились с использованием машины для сварки трением безре- дукторного типа, которая была сконструирована и изготовлена нами для THE EFFECTS OF ROTATION SPEED AND FRICTION TIME FOR JOINING OF STEELS 667 этой цели. После сварки трением для определения микроструктурных изменений в области границы раздела сваренных образцов использова- лись методы оптической и сканирующей электронной микроскопии, а также энергодисперсионная рентгеновская спектроскопия и рентгеноди- фракционный анализ. Для определения механических свойств сваренных образцов проводились исследования микротвёрдости и испытания на раз- рыв. Результаты экспериментов показывают, что отпущенная сталь AISI 4340 может соединяться с двухфазной нержавеющей сталью AISI 2205 методом сварки трением с получением сварного шва достаточной прочно- сти. Значения прочности на разрыв также подтвердили этот результат и то, что в области контакта не образуются интерметаллические фазы. Мак- симальная прочность на разрыв 635,66 МПа была достигнута для соеди- нений, полученных при следующих условиях сварки: скорость вращения – 2200 об/мин., давление трения – 40 МПа, давление прессования – 80 МПа, время трения – 6 с и время прессования – 3 с. Key words: AISI 4340, AISI 2205, friction welding, rotation speed, friction time. (Received January 20, 2015) 1. INTRODUCTION Duplex stainless steel (DSS) is a well-known material for its excellent strength and corrosion resistance. However, joining DSS plates by the fusion welding causes significant reduction in the mechanical proper- ties because of microstructure changes during weld solidification. It is very essential to maintain characteristics of the weld zone to use DSS in servicing highly critical environments, such as ocean mining ma- chinery, oil and gas pipelines, desalination plants, chemical tankers of ships, etc. DSS has ferrite () and austenite () in an approximately equal proportion, which possess body centred cubic (b.c.c.) and face centred cubic structure (f.c.c.) respectively [1]. During the controlled alloying process of the DSS under equilibrium conditions, ferrite- promoting elements (Cr, Mo, Mn, W, Nb, Si, Ti, and V) will concen- trate by diffusion in the ferrite. At the same time, austenite- promoting elements (Ni, C, N, Co, and Cu) will concentrate by diffu- sion in the austenite phases. This gives the even formation of dual phase microstructure [2—3]. However, the welding of DSS forces the microstructure to remain in an excessive ferritic nature, because of the higher amounts of ferrite promoting elements in its chemical com- position, and due to faster cooling rate. Austenite usually nucleates in the temperature range 1200—900C. During cooling, the weld zone re- mains in this range of temperature for a very short period of time, i.e. from 4 s to 15 s. Thus, the arc energy and filler metal composition play a major role in microstructural stability after welding [4]. Tempered types of steel are machinery manufactured steels with and 668 U. CALIGULU, M. YALCINOZ, N. KATI et al. without alloy, whose chemical compositions, especially in terms of car- bon content, are suitable for hardening and which shows high tough- ness under a specific tensile strength at the end of the tempering pro- cess. Tempered types of steel, due to their superior mechanical proper- ties, acquired at the end of the tempering process, are used in a wide range including the manufacture of parts such as various machine and engine parts, forging parts, various screws, nuts and stud bolts, crankshafts, shafts, control and drive components, piston rods, vari- ous shafts, gears. For this reason, tempered steels are the type of steel used and produced at the highest rate after the unalloyed steels and construction steels. These steels constitute the most important part of the machinery-manufacturing steels. Generally, such steels are used for the production of fitting, axle shaft, the shaft and the gear [5—9]. Friction welding is a solid state joining process, which can be used to join a number of different metals. The process involves making welds in which one component is moved relative to, and in pressure contact, with the mating component to produce heat at the faying surfaces. Sof- tened material begins to extrude in response to the applied pressure, creating an annular upset. Heat is conducted away from the interfacial area for forging to take place. The weld is completed by the application of a forge force during or after the cessation of relative motion. The joint undergoes hot working to form a homogenous, full surface, high- integrity weld. Friction welding is the only viable method in this field to overcome the difficulties encountered in the joining of dissimilar materials with a wide variety of physical characteristics. The ad- vantages of this process are, among others, no melting, high reproduc- ibility, short production time and low energy input [10—20]. Urena [21] developed the optimum welding condition for joining 2205 DSS using plasma—arc welding. Ku et al. [22] welded 2205 duplex stainless steel by electron beam welding and analysed the mechanical properties, microstructure and corrosion properties of the weldment. Kannan and Murugan [23] observed the effects of FCAW process pa- rameters on DSS clad quality. Laser beam welding parameters were op- timized by Reisgen et al. [24] and they found that, RSM can be consid- ered as a powerful tool in experimental welding optimization. As the weld bead quality depends on the process parameters, it is essential to study the effects of process parameters on weld quality. Dobrovidov [25] investigated the selection of optimum conditions for the friction welding of high speed steel to carbon steel. Ishibashi et al. [26] chose stainless steel and high-speed steel as representative materials with an appreciably difficult weldability, and their adequate welding condi- tions were established. The distributions of the alloying elements at and near the weld interface with sufficient strength were investigated using X-ray microanalysis. Mumin Sahin [9—10] analysed the varia- tions in hardness and microstructure at the interfaces of friction weld- THE EFFECTS OF ROTATION SPEED AND FRICTION TIME FOR JOINING OF STEELS 669 ed steel joints. While using austenitic stainless steel, negative metal- lurgical changes like delta ferrite formation and chromium carbide precipitation between grain boundaries took place during fusion weld- ing. These changes were eliminated by friction welding. The effect of friction time on the fully plastically deformed region in the vicinity of the weld was investigated by Sathiya et al. [27]. Ananthapadmanaban et al. [28] reported the effect of friction welding parameters on tensile properties of steel. Satyanarayana et al. [29] joined austenitic—ferritic stainless steel (AISI 304 and AISI 430) using continuous drive friction welding and investigated optimum parameters, microstructures- mechanical property and fracture behaviours. Yilmaz [30] investigat- ed the variations in hardness and microstructures in the welding zone of friction welded dissimilar materials. Paventhan et al. [31] investi- gated optimization of friction welding process parameters for joining carbon steel and stainless steel. In this study, the objective of the present work is to examine the ef- fects of rotation speed and friction time for joining of AISI 4340—2205 steels by friction welded. 2. EXPERIMENTAL AISI 4340 tempered steel and AISI 2205 duplex stainless steel of 12 mm diameter were used to fabricate the joints in this study. Table 1 illustrates the chemical compositions of the base metals. The friction- welding tests were carried out using a direct-drive type friction- welding machine. Table 2 was given mechanical properties and Table 3 was given physical properties of AISI 4340 and AISI 2205 steels. Table 4 illustrates the experimental conditions. The experimental set-up is TABLE 1. Chemical compositions of test materials. Materials Alloy Elements (% wt.) C Mn Si P S Cr Mo Ni N Cu AISI 4340 0.4 0.8 0.3 0.035 0.040 0.9 0.3 2.00 — — AISI 2205 0.018 1.686 0.309 0.026 0.003 22.333 3.379 4.932 0.191 0.097 TABLE 2. Mechanical properties of copper and low carbon steel. Materials Tensile Strength, MPa Yield Strength 0,2%, MPa Elongation, % Microhardness, HV AISI 4340 659 400 20,98 201 AISI 2205 956 620 20 328 670 U. CALIGULU, M. YALCINOZ, N. KATI et al. shown in Fig. 1. After friction welding procedure, specimens were divided into sec- tions transversely in order to investigate the microstructural varia- tions from the centre to the outside of the weld. Transverse sections TABLE 3. Physical properties of copper and low carbon steel; –thermal ex- pansion coefficient (20—800C), –thermal conductive (20C), –electrical resistance (20C), E–elastic modulus (20C). Materials 10 6 K 1 , W/(mK) , nm E, GPa AISI 4340 12.3 44.5 248 190—200 AISI 2205 14.7 19 85 200 TABLE 4. The process parameters used in the friction welding. Sample No. Welding parameters Rotating speed, rpm Friction pressure, MPa Forging pressure, MPa Friction time, s Forging time, s Axial shortening, mm S1 2200 40 80 6 3 4.50 S2 2200 40 80 10 5 4.78 S3 2100 40 80 6 3 3.44 S4 2100 40 80 10 5 3.96 S5 2000 40 80 6 3 2.20 S6 2000 40 80 10 5 2.60 Fig. 1. Experimental set-up [17]. THE EFFECTS OF ROTATION SPEED AND FRICTION TIME FOR JOINING OF STEELS 671 were prepared, and then, grinding and polishing 3 m diamond paste were made in order to conduct metallographic examination of the joined materials. The specimens were etched chemical in a solution for AISI 4340 2% HNO3  98% Alcohol and in a solution for AISI 2205 25% HNO3  75% pure water to conduct the microstructural examination (7.5 V  30 s) The microstructures of the joints were observed using Optical Micros- copy (OM), the Energy Dispersive Spectroscopy (EDS) and X-Ray Dif- fraction (XRD). Microhardness measurements were taken under a load of 50 g. Tensile tests were conducted at room temperature with 10 2 mms1 crosshead rate. 3. RESULTS AND DISCUSSION 3.1. Microstructure The macroview of specimens S1, S2, S3, S4, S5, and S6 welded under different welding conditions is shown in Fig. 2. Visual examination of the welded specimens showed uniform weld joints. As it can be seen in Fig. 2, the amount of flash increases with an increase in friction time, friction pressure, and rotation speed. In the case that the dissimilar materials are joined using the friction welding method, the formation of the flash depends on the mechanical properties of two parent mate- rials. Maximum post-welding axial shortening is measured 4.78 mm on S2 specimen. The flash obtained was symmetric, which indicated plastic defor- mation on both the rotating and upsetting (reciprocating) side. The in- tegrity of the joints was evaluated for the friction-welded joints. The friction-processed joints were sectioned perpendicular to the bond line and observed through an OM microscope. It can be clearly seen that, there were no crack and voids in the weld interface. From the microstructural observations, the microstructures formed Fig. 2. Overview of friction welded AISI 4340—AISI 2205 steels. 672 U. CALIGULU, M. YALCINOZ, N. KATI et al. interface zone during or after FW processes, there are three distinct zones across the specimens identified as unaffected zone (UZ), de- formed zone (DZ) and transformed and recrystallized fully plastic de- formed zone (FPDZ). Typical grain refinement occurred in the DZ re- gion by the combined effect of thermal and mechanical stresses (Fig. 3). A typical micrograph showing the different morphologies of the microstructure at different zones of the friction processed joint is shown in Fig. 3. It was observed that the rotational speed had an effect on geometry and width of the weld zone. The mechanical deformation and the fric- tional heat at the interface that dissipated through the parent materi- als results in a temperature gradient causing zones of materials with different microstructure. Although this condition causes lower cool- ing rates and a wider heat affected zone (HAZ), higher rotational speed leads narrower FPDZ due to a greater volume of viscous material transferred out of at the interface. It is a known fact that when pres- sure is used to bring joint pair together by plastic deformation results in dynamic recrystallization leading to a grain refinement in the cen- tral region of the weld. The effect of increasing rotational speed on the friction welded joint is an increase in both temperature gradient and axial shortening as a result of more mass being transferred out of the welding interface. High rotational speed can cause local heating at the interface, thus reaching a high temperature in a short time. This con- dition causes lower cooling rates and a wider HAZ, as a consequence of a greater volume of viscous material transferred out of the interface. AISI 4340 tempered steel was greatly deformed by the severe plastic deformation and frictional heat near the weld zone. There were no blanks, cracks or porosities in the weld was determined (Fig. 4). Fig. 3. Regions, which occurred microstructural chances [32]. THE EFFECTS OF ROTATION SPEED AND FRICTION TIME FOR JOINING OF STEELS 673 During the friction welding process, the temperature at the inter- face was measured by IGA 15 PLUS detector, and the temperature val- ues at interface of the joints are given in Fig. 5. It shows the tempera- ture that occurred at the interface of the joint comes close to melting point of AISI 4340 tempered steel (1065—1198C), which can reach be- tween A3 temperature and the melting point of AISI 4340 tempered Fig. 4. Optical micrograph taken from the welding interface of the specimens S1, S2, S3, S4, S5, and S6, respectively. 674 U. CALIGULU, M. YALCINOZ, N. KATI et al. steel. 3.2. Tensile Shape and measurements of the tensile specimens were seen in Fig. 6. The results of tensile tests were given in Figs. 7 and 8, respectively. As Fig. 5. The temperature at the interface of FW joints. Fig. 6. Shape and measurement of the tensile test specimens [33]. Fig. 7. Macrophoto of tensile test results of friction-welded joints. THE EFFECTS OF ROTATION SPEED AND FRICTION TIME FOR JOINING OF STEELS 675 it is clearly seen in Fig. 8, the tensile strength slightly increased while the rotation speed increased. Results of the tensile tests concluded that all joints were fractured by necking at the tempered steel side (see Fig. 7). Current studies in literature report that a higher bonding tempera- ture results in profuse interdiffusion and better coalescence of mating surfaces. Plastic deformation detected in the specimens after the welding was not observed. However, increasing bonding temperature due to the in- crease of the rotational speed and the friction time also promotes the growth of brittle intermetallic, which adversely affects the bond strength in turn. Therefore, low elongation and strength values can be attributed to presence of aligned tempered steel precipitation reducing these properties. Maximum tensile strength and minimum tempera- ture of the FW joints was achieved at the rotational speed of 2200 rpm in S1, 635.66 MPa and 1065C, respectively. This increase in tensile strength was related to the heat input and high plastic deformation occurring at the component interface as a re- sult of the rotational speed and the axial pressure. Minimum tensile strength and maximum temperature of FW joints was obtained at 2000 rpm in specimen S6, 601.60 MPa and 1198C, respectively. This decrease in tensile strength was associated with the reactions taking place at the HAZs of the tempered steel side. Longer time intervals al- lowed thermal energy to propagate along the axial direction of the work materials, and as a consequence, a bulk volume of material was heated. Therefore, longer time intervals led to lower cooling rates and a wider HAZ. As the friction time decreased, the joining efficiency steeply increased, and reached a maximum value at the rotational speed of 2200 rpm for 6 s with 635.66 MPa and then decreased again. Fig. 8. Tensile test results of friction-welded joints. 676 U. CALIGULU, M. YALCINOZ, N. KATI et al. Under given conditions (2200, 2100, and 2000 rpm rotation speeds), tensile strengths were close to parent material, and slightly increased at increased rotation speeds. 3.3. Fractography Figure 9 shows the images of the fracture surfaces resulting from the tensile test for the friction-welded specimens S1 and S6. Examining the fracture surface images, fractures resulting from the tensile test were mostly on the AISI 4340 tempered steel side, and it was observed that the fracture surface contains ductile dimples, formed by the mi- crovoid coalescence mechanism and facets associated with the cleavage fracture. The dimples are believed to initiate at the second-phase parti- cles or small inclusions within the ferrite and austenite phase of the AISI 2205 duplex stainless steel, whereas the facets represent brittle fracture occurring along the cleavage planes of the phase. As illustrat- ed in Fig. 9, the number of ductile dimples increases with decreasing rotation speed. This type of fracture topography is classified as the Fig. 9. Micrograph of the tensile fracture surfaces of S1 and S6 specimens ob- served by SEM. THE EFFECTS OF ROTATION SPEED AND FRICTION TIME FOR JOINING OF STEELS 677 quasi-cleavage. In generally, mechanism of ductile fracture was ob- served in the samples. 3.4. Microhardness Microhardness measurements in the direction perpendicular to the weld interface of the friction-welded joints for specimens S1—S6 are given in Figs. 10 and 11. As seen in these figures, a significantly similar trend is observed in the microhardness profiles of all specimens. The increasing hardness in the welding interface can be directly as- sociated with the microstructure in the welding interface as a result of the increasing heat input and severe plastic deformation. Microhard- ness values can be increased with increasing the rotational speed and friction time. This can be explained with the C, Cr, Mn, Fe, and Ni dif- Fig. 10. Schematic illustration of microhardness distribution across the weld- ing interface [33]. Fig. 11. Microhardness distribution across the welding interface of friction- welded specimens. 678 U. CALIGULU, M. YALCINOZ, N. KATI et al. fusion of parent materials at weld interface, thus it has relatively low- er hardness. The increase in the hardness in the AISI 4340 side can be attributed to the work hardening of the duplex stainless steel. Besides, the main reason for this is associated with the temperature increase in the interface, which is caused by deformation and friction. The tem- perature increase caused by the increase in the friction time enhances the viscosity of the material in the interface and enables its quick re- moval out of the interface. The increase in the upset time, on the other hand, is thought to create a forging effect on the AISI 4340 side and cause an increase in hardness. 3.5. X-Ray Diffraction and EDS Analysis Figure 12 illustrates X-Ray diffraction across the interface of the S1 specimen. In the X-Ray analysis, like Fe—Ni, Fe—Cr—Ni, Fe—Cr, Cr23C6, Cr—Fe—Ni—C, and Cr7C3 phases were determined (Fig. 12). In the EDS analysis, as well as C, Cr, Mn, Fe, and Ni elements, non-intermetallic phases determined in the welding interface were detected. In the 60 m distance, from AISI 4340 tempered steel to AISI 2205 duplex stainless steel, Fe, C, and Mn diffusion, and in equal distance from AISI 2205 duplex stainless steel to AISI 4340 tempered steel, Cr and Ni diffusion occurred (Table 5 and Fig. 13). The frictional heat generated at the interface (under identical weld- ing conditions) would be high for low-density elements due to their high boundary friction coefficients and low thermal conductivity com- pared to high-density elements. The welding procedure made with dis- Fig. 12. The result of XRD analyses of S1 specimen. THE EFFECTS OF ROTATION SPEED AND FRICTION TIME FOR JOINING OF STEELS 679 similar materials exhibits wider plasticized zone in the middle of the welding interface. As for low-density elements, content of intermixing elements is higher in comparison to high-density elements. This is caused by the fact that higher flow required for the high-density ele- ments restricts movement comparing to the low-density elements, which can move freely. 4. CONCLUSION AISI 4340 tempered steel and AISI 2205 duplex stainless steel were joined by friction technique using different process parameters. Con- clusions drawn based on the results of microstructure analysis, hard- ness, and tensile tests are presented below. This study concluded that AISI 4340 tempered steel could be joined according to Table 4 successfully to AISI 2205 duplex stainless steel using the friction welding technique. Comprehensive microstructural investigations for AISI 4340—2205 friction-welded joints revealed that there are different regions at the welding interface, the width of fully plasticized deformed zone decreases when rotational speed and friction pressure increase. The higher microstructural changes take place in the HAZs. An in- TABLE 5. Values of concentrations taken from EDS analyses across the weld- ing interface of S1 specimen. EDS point Alloying elements, % wt. C Cr Mn Fe Ni 1 11.15 11.56 1.22 71.73 4.34 2 14.13 3.46 0.74 80.57 1.10 3 17.18 1.01 0.74 78.83 2.24 Fig. 13. EDS analyses across the welding interface of the friction-welded spec- imen S1. 680 U. CALIGULU, M. YALCINOZ, N. KATI et al. crease in the contraction of the samples is observed after increasing the friction welding rotation speeds. The width of HAZ is mainly af- fected by friction time and rotation speed. This infers that the width and formation of HAZs, which occurred as a result of the reactions tak- ing place at the welding interface, have an adverse effect on the me- chanical strength and, consequently, the quality of the friction-welded joints. The highest deformation was always at AISI 4340 tempered steel side, and in all samples, the original structure was preserved in the undeformed region. A rotation speed of 2000 rpm was not completely sufficient to join AISI 4340—2205 steels by friction welding, but a rotation speed of 2200 rpm was sufficient for joining these materials. The maximum tensile strength of 635.66 MPa could be obtained for the joints welded under the welding conditions of rotation speed of 2200 rpm, friction pressure of 40 MPa, forging pressure of 80 MPa, friction time of 6 s and forging time of 3 s. All samples were subjected to tensile testing showed brittle characteristics of the fracture topog- raphy in the partially deformed region on the AISI 4340 steel side (Fig. 8). The increase in hardness at the HAZs is attributed to the micro- structural transformation that occurs during the friction welding pro- cess. The strengthening effect observed in this region is mostly a direct result of the rapid cooling from the welding temperature. 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