Parametric Investigation of Continuous Drive Friction Welding of Dissimilar Steel Bars (AISI 304H and AISI 4130)

Abstract

Friction welding is a solid-state joining process that merges materials under compressive force contact of workpieces rotating or moving relative to one another. Conventional fusion welding of dissimilar steel bars is not feasible due to various draw backs; hence friction welding is one of the least sensitive of all welding methods for joining materials with wide differences in physical properties, since the heat is generated directly at the weld where the bond is to be developed. The purpose of the current study is to investigate parameters(rotational speed, friction time, and burn-off length) continuous drive friction welding in joining both AISI 304H and AISI 4130 steel bars using universal lathe machine. Chemical composition of the materials is tested in a spectrometer. Response surface methodology is used for designing the experiment. Tensile strength and microhardness of the weldment is investigated to identify their mechanical properties. The tensile strength increased steadily as the rotational speed increased, it also increased up to some amount and started declining when the friction time gets higher, and it decreases when the burn of length was in its least and higher level. The hardness of the weldment is higher at the weld interfaces and showed an inverse relationship with the strength of weldment. Optimization is carried out by response surface methodology. Besides, the working temperature is measured using infrared thermometer and the tensile strength of the weldment exhibits an adequate joining of the dissimilar steel bars; thus maximum tensile strength is found in the weakest part of AISI 304H bar.