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Article history: Friction welding is one of the most economical and highly practicable methods in joining similar and
Received 28 February 2013 dissimilar metals. In this study, high-quality welds are produced in the super duplex stainless steel by
Received in revised form 30 May 2013 continuous drive friction welding successfully. Design of experiment was done using central composite
Accepted 9 June 2013
design of response surface methodology. In the present work, the microstructure and mechanical prop-
Available online xxx
erties of friction welded super duplex stainless steel (UNS S32760) were examined. The base material
has a microstructure consisting of the ferrite matrix with austenite islands. Ferrite content was analyzed
Keywords:
through the phase analyzer software and found that it is in the range of 4255% in all weld metals. The
Phase analysis
Tensile properties
phases were further analyzed through X-ray diffraction method. All the weld metals have higher hardness
Impact strength than the base metals. Weld transverse tensile failures consistently occurred away from the weld zone and
Hardness exhibit more hardness, yield and ultimate tensile strengths than the base material. The austenite content
Microstructure characterization increases with nitrogen concentration. Nitrogen could enhance the yield stress and ultimately tensile
strength of super duplex stainless steel. Secondary phase precipitation is not observed in the welded
joint probably due to the shorter heating times.
2013 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
1526-6125/$ see front matter 2013 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.jmapro.2013.06.010
Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
duplex stainless steel joints using friction welding process. J Manuf Process (2013), http://dx.doi.org/10.1016/j.jmapro.2013.06.010
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Table 1
Base material chemical composition (wt.%).
Elements Cu C Si Mn P S Cr Mo Ni N
(%) 0.429 0.007 0.538 0.962 0.026 0.001 24.27 3.07 6.15 0.240
without ller material and ArN2 gas mixture was used as a shiel- emphasis on the precipitation of sigma phase. The effect of lat-
ding media. The study was concentrated only on nitrogen content tice mist strains due to the precipitation of sigma phase on
in the weld metal. The effect of nitrogen on the microstructure the mechanical properties were analyzed and discussed. Topo-
and corrosion properties of the weld metal was investigated. It laka and Labanowski [10] studied the effect of heat treatments
is found that, nitrogen content of the weld metal increased and and the resulting changes in microstructure on mechanical proper-
brought reductions in the ferrite content and the quantity of Cr2 N ties, mainly impact toughness, of commercial 2205 duplex stainless
nitride precipitates in the weld. The critical pitting temperature and steel and higher alloy super duplex 2507 grade. The results conrm
pitting potential increased and corrosion rate decreased with the
increasing of nitrogen content of the weld metal.
Due to its low nickel content, duplex stainless steel (DSS) has
good weldability. However, the melting and solidication asso-
ciated with fusion welding process destroy the favorable duplex
microstructure of this stainless steel. Moreover, detrimental inter-
metallic phases can be formed during the fusion welding process.
Higher ferrite content and coarse grains are other factors which
decrease both the corrosion resistance and the mechanical proper-
ties of welded joints, and it was reported by Sato et al. [6]. Sato et al.
[7] carried out research concerning the gas tungsten arc welding of
duplex stainless steel without ller wire addition with varying the
ArN2 mixed shielding gas atmospheres. Weld metals with differ-
ent nitrogen contents were annealed at 9001300 K and examined
the single effect of nitrogen on the transformation. Nitrogen con-
tent of the weld metal did not inuence the nose temperature and
the time for initiation in timetemperatureprecipitation dia-
grams for , but did decreases the content after annealing for
long times. The obtained results were correlated with the nitrogen
content and microstructure of the weld metals. Sato and Kokawa
[8] investigated the effect of crystallographic orientation relation- Fig. 2. Friction welding machine.
Table 2
Friction welding parameters and their levels.
Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
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Table 3
Central composite design for four factors.
1 1 1 1 1 40 122 1000 2
2 1 1 1 1 120 122 1000 2
3 1 1 1 1 40 170 1000 2
4 1 1 1 1 120 170 1000 2
5 1 1 1 1 40 122 2000 2
6 1 1 1 1 120 122 2000 2
7 1 1 1 1 40 170 2000 2
8 1 1 1 1 120 170 2000 2
9 1 1 1 1 40 122 1000 6
10 1 1 1 1 120 122 1000 6
11 1 1 1 1 40 170 1000 6
12 1 1 1 1 120 170 1000 6
13 1 1 1 1 40 122 2000 6
14 1 1 1 1 120 122 2000 6
15 1 1 1 1 40 170 2000 6
16 1 1 1 1 120 170 2000 6
17 1 0 0 0 40 146 1500 4
18 1 0 0 0 120 146 1500 4
19 0 1 0 0 80 122 1500 4
20 0 1 0 0 80 170 1500 4
21 0 0 1 0 80 146 1000 4
22 0 0 1 0 80 146 2000 4
23 0 0 0 1 80 146 1500 2
24 0 0 0 1 80 146 1500 6
25 0 0 0 0 80 146 1500 4
26 0 0 0 0 80 146 1500 4
27 0 0 0 0 80 146 1500 4
28 0 0 0 0 80 146 1500 4
29 0 0 0 0 80 146 1500 4
30 0 0 0 0 80 146 1500 4
31 0 0 0 0 80 146 1500 4
that high temperature service of duplex stainless steel should by appropriate selection of the heat input and interpass tempera-
be avoided. Precipitations of secondary phases (mainly phase) ture.
strongly deteriorate the mechanical properties of steel but some Deng et al. [14] studied the effect of annealing temperature
amount of these phases could be acceptable in the microstructure on the microstructure of each phase and the associated corro-
depending upon the application of the steel. Martins et al. [11] sion behavior of a SDSS modied by mischmetal, thus determining
investigated the characters of the microstructure of a super duplex the optimal annealing temperature where the SDSS exhibits the
stainless steel in the cast and solution annealed conditions, and they best pitting corrosion resistance. It is observed that the secondary
determined the inuence of aging heat treatments on its impact phases (sigma phase-secondary austenite) and chromium nitrides
strength, based on Charpy impact tests applied on to V-notched can be observed after quenching from solution annealing temper-
test specimens. They reported that, the sigma phase was found to atures and they have different inuence on the corrosion behavior
begin precipitating at heat treatment temperatures above 760 C of SDSS. Fargas et al. [15] analyzed the kinetics and the mecha-
and dissolves completely above 1040 C, with the highest peak con- nisms of wear that develop in SDSSs with different amounts of
centration of this phase appearing at close to 850 C. Martins and sigma phase and their correlation to microstructural characteris-
Casteletti [12] studied the inuence of several heat treatment tem- tics. Hua et al. [16] investigated the pitting corrosion resistance
peratures on the microstructure and mechanical properties of an of super duplex stainless steel with different annealed tempera-
ASTM A 890/A 890M Gr6A super duplex stainless steel. They found tures in the range of 10301200 C without apparent precipitation
that the increase in hardness and the decrease in impact toughness of deleterious phases. Youseeh et al. [17] optimized the pulsed
of these materials are directly correlated with the increase in sigma current gas tungsten arc welding (PCGTAW) parameters for the
phase concentration in their microstructure, which tended to pre- corrosion resistance of super duplex stainless steel (UNS S32760)
cipitate into ferrite/austenite interfaces. When the sigma phase was welds. The Taguchi method was found to be promising technique to
completely dissolved by the heat treatment, the materials hard- obtain the optimum conditions for this study. Moreover, the exper-
ness was determined by the volumetric concentration of ferrite imental results obtained conrm the adequacy and effectiveness of
and austenite in the microstructure, and the energy absorbed in this approach.
the impact test reached approximately 220 J at room temperature. From these observations made out of the above literature, it is
Sathiya et al. [13] investigated the effect of two different shiel- clear that numerous research studies have focused on the effect of
ding gases (argon and helium) with gas tungsten arc welding of various heat treatments and their effects and corrosion studies on
duplex stainless steel and evaluated the mechanical and metallur- weld metals. Only a very few literatures are available on welding
gical characters of the welded joint. It is found that helium-shielded of super duplex stainless steel.
welds exhibited higher toughness due to large Mn content and it The present work is an experimental study of friction weld-
also exhibited a smaller amount of ferrite phase and larger amount ing of super duplex stainless steel. In this study, the super duplex
of austenite phase in the weld metal. Due to the high value of the stainless steel materials with the same composition were welded
Creq /Nieq ratio, a large amount of ferrite is present in the argon- with different process parameters using the same procedure. The
shielded weld metal. Chromium nitride precipitation is observed in mechanical properties of the joints were determined by tensile
the argon-shielded weld metal. For the argon-shielded weld metal test, impact test and the results were compared with individual
an even phase balance (55% ferrite and 45% austenite) is achieved parameter effects. The tensile and impact fracture surface were
Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
duplex stainless steel joints using friction welding process. J Manuf Process (2013), http://dx.doi.org/10.1016/j.jmapro.2013.06.010
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analyzed through SEM and the hardness variations were measured. off length (BOL) and speed of rotation were chosen. Each indepen-
The microstructure and phase analysis in the welding zones were dent variable had 3 levels which were 1, 0 and +1. The welding
obtained. X-ray diffraction was adopted for phase identication in parameters and their levels are presented in Table 2.
the weld zone. The chemical composition of the weld was stud- A total of 31 experiments (including seven replicates of center
ied and the ratio of Nieq and Creq were calculated. An experimental point with the side of coded value 0) were conducted in random
procedure is realized in laboratory conditions on friction welding. order according to a CCD conguration for four factors generated
from Minitab 16 software contains 16 cube points, 8 axial points
2. Experimental details and 7 center points (see Table 3). A continuous drive friction weld-
ing machine (as shown in Fig. 2) with a maximum load of 150 kN
Super austenitic stainless steel (UNS S32760) specimens of was used for welding.
16 mm diameter and 100 mm length (each side dimensions) were The super duplex stainless steel friction welded samples are
joined using friction welding process. The base material chemical presented in Fig. 3.
composition was analyzed using an optical emission spectrometer The specimens were mounted and later attened and then pol-
and their values are presented in Table 1. ished using SiC abrasive paper with grit ranges from 180 to 1200.
The base metal is employed in the study is UNS S32760 super Then the samples were lightly polished using 3 m diamond pastes.
austenitic stainless steel. Optical micrograph and phase mapping Samples were then washed, cleaned by acetone and then dried fol-
of the base metal is presented in Fig. 1(a) and (b). lowed by electrolytic etching in 10% oxalic acid at 9 v for 30 s as per
A four-factors, three-level Central Composite design (CCD) was ASTM E3-11. Chemical composition of the weld metal was found
used to determine the optimal factors of Friction welding process from spectra chemical analysis. Ferrite percentage was measured
for super duplex stainless steel (UNS S32760). Four independent using ferrite scope and also the percentage of ferrite was calculated
variables namely friction pressure (FP), upset pressure (UP), burn using Creq and Nieq . The specimens for Charpy test were prepared
Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
duplex stainless steel joints using friction welding process. J Manuf Process (2013), http://dx.doi.org/10.1016/j.jmapro.2013.06.010
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Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
duplex stainless steel joints using friction welding process. J Manuf Process (2013), http://dx.doi.org/10.1016/j.jmapro.2013.06.010
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Table 4
Experimental results (yield strength, tensile strength, impact strength, % of ferrite phase, hardness in the weld).
Exp. no. Friction Upset Burn of Speed (rpm) Yield Tensile Impact % ferrite Hardness
pressure pressure length strength strength strength (J) phase in in the weld
(MPa) (MPa) (mm) (MPa) (MPa) weld
according to the ASTM E23 standards. The impact tests were con- The weld bandwidth was found to be very narrow (Fig. 5(ar))
ducted at room temperature. For the tensile test (ASTM E 8) the in all the welds. The ow pattern was in the peripheral region of
ash was machined from the welds before testing and the base the weld for all the macrostructures (Fig. 5(a)(r)).
materials and joints were machined with 120 mm of gauge length
and 9 mm diameter in all parallel parts. Three measurements were
3.2. Microstructure of the weld and joint interface
taken for each of the welding strengths to calculate their average
data. In order to detect various phases present in the weldments,
The typical weld metal, joint interface and partial deformation
X-ray diffraction (XRD) studies were carried out on planar surfaces
zone (PDZ) microstructure is presented in Fig. 6(a)(f).
of these weld zones. Rigaku Ultimate 3 (Japan) X-ray diffractometer
Fig. 6(a)(f) clearly distinguishes the different zones of the weld
with Cu Ka radiation of wavelength 1.544 A was used. Microhard-
metal. Fusion zone between the weld and the base metal is without
ness survey was carried out using a Matsuzawa-MMT-X7 Vickers
any internal defects. These facts point to the good metallurgic joint
hardness tester at 500 g load for 20 s. The microhardness tests were
of the weld. The weld metal microstructures have ner grain size
performed on a transverse section of the weld center in order
at the nearby zone called the partly deformed zone (PDZ).
to identify the possible effects of microstructural heterogeneities
in the weld. Samples for characterization were prepared using
standard metallographic techniques. The phases were analyzed 3.3. Phase analysis and weld metal chemical composition of the
with optical microscopy and the fracture surfaces were studied weld
through JEOL JSM-5610 LV scanning electron microscope (SEM)
equipped with energy dispersive spectrometer (EDS) to study the Generally, the volume of fraction ferrite content is much higher
quantitative analysis of the welds. In addition the microstructure than the austenite content in the weld and this may be due to
characterization was studied. the loss of low-temperature notch toughness and corrosion resis-
tance in the weld [2,4]. To overcome these issues, careful control
of the weld metal composition and temperature are required dur-
3. Experimental results ing welding. From weld micrographs, the percentage of ferrite and
austenite phases were mapped with image analyzing software and
3.1. Macrograph of the welded joints ferrite number was measured using Fischer Feritscope MP 30 and
their average values are presented in Table 4. From Table 4, it is
The friction welding of super duplex stainless steel was suc- found that the percentage of ferrite phases was lower than the
cessfully conducted without any defects. The typical cross sectional austenite phases for all the welds except three welds.
views of the friction welded samples are presented in Fig. 4(a)(d). The quantitative chemical compositions of the weld metals
Fig. 4 shows the macro-photo of the joint. It was observed that (austenite phase 0.0050.007%C, 0.6341.682%Si, 1.051.54%Mn,
the obvious upset collars (ashes) were formed around the weld 0.0580.59%P, 0.851.74%S, 21.9925.06%Cr, 3.043.21%Mo,
interface on both the sides. The macrographs of the friction welding 5.637.93%Ni, 0.1920.219%Cu, 0.2070.242%N and ferrite phase
of super duplex stainless steel joints are presented in Fig. 5(a)(r). 0.0020.005%C, 0.5911.214%Si, 0.981.84%Mn, 0.0520.52%P,
Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
duplex stainless steel joints using friction welding process. J Manuf Process (2013), http://dx.doi.org/10.1016/j.jmapro.2013.06.010
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0.931.95%S, 22.8925.01%Cr, 3.023.2%Mo, 5.87.13%Ni, From Fig. 9, it is clearly seen that the fractures occur away from
0.1930.212%Cu, 0.2250.247%N) were conrmed by EDS inves- the weld joint. The tensile tested typical load vs displacement curve
tigations. Typical EDS spectrum for austenite (white color) and is presented in Fig. 10.
ferrite (black color) phases are shown in Fig. 7. From load vs displacement (Fig. 10) graph, it can be observed
The Creq /Nieq ratio, calculated from the following equations [8] that all the strength and ductility obtained values of joint are higher
was 1.59 for base metal and 1.41.75 for weld metal. than the base material strength properties. The area under the
force vs elongation indicates joints have better toughness also.
Creq = %Cr + (1.5)%Si + 1.4%Mo + %Nb-4.99 (1)
The fractured surface of tensile specimen is analyzed using SEM.
and The fracture surface of the tensile tested fractrograph is shown in
Fig. 11(a)(f).
Nieq = %Ni + 30%C + (0.5)%Mn + 26(%N-0.02) + 2.77 (2)
The above metallographic results were further conrmed by 3.5. Toughness of the weld
XRD analysis. The typical XRD pattern is presented in Fig. 8(a)(e).
In order to evaluate the Charpy impact toughness values of
3.4. Tensile strength of the joints welded joint, a series of Charpy V-notch test was carried out from
friction welded joints at room temperature and the tested samples
The main aim of the tensile test is to evaluate the strength and are shown in Fig. 12.
plasticity of welding joints and examine the inuence of welding Notches were prepared exactly midpoint of the weld. The value
defects on the joint performance. The test is done on computer obtained from the testing is shown in Table 4. The impact toughness
interface electronic universal testing machine. The transverse ten- of unwelded base metal was found to be 27 J, which was compara-
sile strength and yield strength of all joints have been evaluated. tively lower than the weld metal impact strength. From Table 4 it is
The tensile test results of friction welding of super duplex stainless clear that weld joints exhibit higher impact toughness values and
steel joints are presented in Table 4. From Table 4, it is clear that the enhancement in impact strength (toughness) value is approxi-
the weld metal tensile strength is much higher than the base metal mately 45% compared to the base metal value. The fractured surface
tensile strength which is in line with the microhardness results. The of impact specimens was analyzed using SEM. The fractured surface
typical tensile tested samples are presented in Fig. 9. of the impact tested fractrograph is shown in Fig. 13(a)(h).
Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
duplex stainless steel joints using friction welding process. J Manuf Process (2013), http://dx.doi.org/10.1016/j.jmapro.2013.06.010
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Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
duplex stainless steel joints using friction welding process. J Manuf Process (2013), http://dx.doi.org/10.1016/j.jmapro.2013.06.010
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Fig. 10. Load vs displacement curve for Tension test (Exp. no. 11).
Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
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due to very ner grains observed in the weld zone. The effects of
individual process parameters on friction welding with respect to
the tensile strength relationship is plotted in graph as shown in
Fig. 16(a)(d).
At a constant low friction pressure (40 Mpa) and low rotat-
ing speed (1000 rpm) for burn of lengths 2 mm and 6 mm there
is decrease in tensile strength as upset pressure increases from
122 MPa to 170 MPa (Fig. 16(a)). Whereas at a constant low fric-
tion pressure (40 MPa) and high speed (2000 rpm) for 2 mm and
6 mm of burn of lengths, the upset pressure increases from 122 MPa
to 170 MPa and also increases the tensile strength of the joints
(Fig. 16(b)). There is a gradual decrease in tensile strength as
upset pressure increases when all other parameters are constant
(Fig. 16(c)). Tensile strength decreases at 1500 rpm then again
increases at 2000 rpm while all other parameters are constant Fig. 12. Typical impact tested samples.
Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
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(Fig. 16(d)). However, all the welded samples failed away from solution strengthening effect, the dissolved nitrogen in austenite
the joint interface (Fig. 9). The tensile tested fracture surface phase enhances the tensile strength of the welds.
(Fig. 11(a)(f)) revealed the ductile mode fracture with very ne The individual effect of friction welding parameters with respect
dimples. Due to very ne dimples size (Exp. no. 1), the tensile to the toughness of the welds is plotted in the graph as shown
strength is higher than the other weld strength and due to solid in Fig. 17(a)(d). From Table 4, it is clearly seen that, the friction
Please cite this article in press as: Udayakumar T, et al. Experimental investigation on mechanical and metallurgical properties of super
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duplex stainless steel joints using friction welding process. J Manuf Process (2013), http://dx.doi.org/10.1016/j.jmapro.2013.06.010