Int J Adv Manuf Technol (2017) 88:1299–1307
DOI 10.1007/s00170-016-8763-5
ORIGINAL ARTICLE
Study on microstructure and mechanical properties of dissimilar
steel joint developed using friction stir welding
Gaurav Sharma 1 & D. K. Dwivedi 1
Received: 30 July 2015 / Accepted: 11 April 2016 / Published online: 12 May 2016
# Springer-Verlag London 2016
Abstract In the present study, microstructure and mechanical
properties of dissimilar weld of structural steel and ferritic
stainless steel (FSS) plates of thickness 3 mm were investigat-
ed. The plates were butt welded by friction stir welding and
defect-free welds were produced at a traverse speed of 20 mm/
min and rotational speed of 508 rpm using a tungsten carbide
tool. The weld joint consisted of alternate bands of both steels
resembling an onion ring pattern. In the weld joint, six distinct
regions were found including both the base metals. The stir
zone of structural steel revealed refined grain structure of fer-
rite, pearlite, and martensite whereas in ferritic stainless side,
highly refined ferritic grains with grain boundary martensite
was observed and also confirmed by x-ray diffraction (XRD).
The hardness of the weld joint varies from 186 to 572 HV.
This scatter of hardness in stir zone is due to the presence of
metal from both sides. The ultimate tensile and yield strengths
of the transverse weld specimens was higher than the struc-
tural steel base metal whereas lower than the ferritic stainless
steel, having fracture from structural steel side.
Keywords Friction stir welding . Microstructure . Tensile
properties . Structural steel . Hardness
* Gaurav Sharma
gauraviitr1992@gmail.com
1
Department of Mechanical and Industrial Engineering, Indian
Institute of Technology Roorkee, Roorkee, Uttarakhand 247667,
India
1 Introduction
Dissimilar metal joining is a fast growing area over a past few
years as it brings together metal systems having extremely
different properties [1]. The major application for joining dis-
similar metals is in the development of complex assemblies to
create hybrid structures. The fundamental challenge of joining
dissimilar steel is incompatibility in mechanical, physical, and
chemical properties to produce an acceptable joint in terms of
joint strength, structural integrity, and efficiency [2]. The dif-
ference in physical, mechanical, and metallurgical properties
of base metals makes dissimilar metal welding, more chal-
lenging than similar metal welding [3]. Ferritic stainless steel
offers suitable corrosion resistance in stress corrosion crack-
ing, pitting, and crevice corrosion [1]. Further, it is considered
more attractive than austenitic stainless steel in application
involving heating/cooling, due to high thermal conductivity
and low thermal expansion coefficient [4, 5]. Fusion welding
of ferritic stainless steel and structural steel is still a challeng-
ing task because it causes degradation in mechanical proper-
ties and corrosion resistance due to grain coarsening, carbide
precipitation, carbon migration, and formation of martensite in
the weld zone.
To overcome all these problems associated with fusion
welding, friction stir welding is a fast growing technique
used for joining similar and dissimilar steels. Due to its
solid state nature, these problems are totally eliminated.
Friction stir welding also provides fine recrystallised
grains in the stir zone, which ensures a significant en-
hancement in the mechanical properties of the weld joint
[6]. Initially, it was mainly used for joining aluminum and
its alloys [7–11] and further, efforts were made to join
high melting point materials [12–14]. Studies also have
been done on calculation of heat generation during fric-
tion stir welding using various models [15, 16]. On the
1300 Int J Adv Manuf Technol (2017) 88:1299–1307

Fig. 1 Photographs of: a friction

stir welding machine and b
appearance during friction stir
welding of steel

other hand, the dissimilar weld joints of ferritic stainless placed on the retreating side (RS) of the weld to avoid
steel and structural steel are widely used for steam, oil, the formation of cavities or groove-like defects. In re-
and gas power plants [1, 6]. In addition to weight and cost verse positioning, material on the advancing side begins
saving, the direct application of this type of joint is in to deform and the material on the RS resists deformation
manufacturing of railway wagons and automotive exhaust due to lower heat generation, which results in a defective
systems. Further, the friction stir welding of ferritic stain- weld due to inadequate material flow [17, 18]. The plates
less steel to other steels was hardly reported. Therefore, were fixed rigidly to the machine bed and cleaned with
attempts have been made in this work to study the micro- acetone before welding. A non-consumable tool of tung-
structure and mechanical properties of the friction stir sten carbide (Fig. 2) was used for welding. Few trial
weld joints of ferritic stainless steel and structural steel. experiments and macro-structural analysis were done to
optimize welding parameters. Figure 3a shows the sur-
face defect due to low rotational speed. Further trial ex-
periments were done for process parameter optimization
2 Experimental procedure
and the optimized process parameters for developing
sound weld are presented in Table 2. During the welding,
In the present study, the plates of structural steel and
compressed air was used for cooling, in order to reduce
ferritic stainless steel of thickness 3 mm was butt joined
the wear and deformation tendency of the tool.
by friction stir welding. The welding was performed in
The samples for metallographic study were sectioned
direction parallel to the rolling direction of the plates by
in the transverse direction of the weld and polished using
using a modified vertical milling machine (Fig. 1a). The
a standard metallographic procedure followed by etching.
chemical composition of both base metals is presented in
The etching of structural steel was done by 2 % nital
Ta b l e 1 . T h e p l a t e s w e r e m a c h i n e d i n
150 mm × 50 mm × 3 mm size for a square butt joint
configuration. Welding of the plates was done in
annealed condition. The annealing of the structural steel
plates was done at 750 °C for 1 h followed by furnace
cooling whereas annealing of the ferritic stainless steel
plates was done at 700 °C for 7 min followed by still air
cooling. The ferritic stainless steel plate was placed on
the advancing side (AS) and the structural steel plate was

Table 1 Chemical composition of the base metals

Base Chemical composition (wt %)

metal
C Mn S Si P Cr Ni Fe

MS 0.243 1.06 0.016 0.097 0.018 0.047 0.022 Balance

FSS 0.03 0.8– 0.03 1.0 0.05 10.8– 1.5
1.5 12.8
Fig. 2 a Schematic diagram showing tool dimension and b WC FSW
tool
Int J Adv Manuf Technol (2017) 88:1299–1307 1301

Fig. 3 Friction stir-welded plates

using WC tool: a surface defect at
low rotational speed and b welded
plate showing no surface defect
with a little flash

Table 2 Friction stir welding parameters scanning electron microscope was used to study the fea-
S. No. Parameter Welding condition
tures of fractured surface of tensile specimens.

1 Welding machine FSW

2 Welding speed (mm/min) 20
3 Results and discussion
3 Rotational speed (rpm) 508
4 Tool pin profile Taper cylindrical
3.1 Macrostructure
5 Tool tilt angle 1.5 °
6 Tool shoulder diameter (mm) 22 Dissimilar steel weld joints between structural steel and ferrit-
7 Pin diameter (mm) 10 and 8 (max. and min.) ic stainless steel plates were developed using friction stir
8 Pin length (mm) 2.75 welding. Figure 1b shows the photograph taken during fric-
tion stir welding of structural steel and ferritic stainless steel.
The weld profile observed for FSW joint is shown in Fig. 3b.
The weld was free from any microscopic cracks and cavities
solution, whereas Villela was used for ferritic stainless
as evident from the macrograph of the weld cross section
steel. The microstructural examination of the weld joint
(Fig. 4). The weld joint consists of alternate bands of both
was done by using a light optical microscope (Dewinter
the steels. This banded structure looks like an onion ring pat-
LT-23B) and scanning electron microscope (QUANTA
tern which is a characteristic of friction stir welding. The gray
200). In order to identify the phase formed in the stir zone
band was mainly composed of structural steel, while the black
and heat-affected zone (HAZ), x-ray diffraction (XRD)
band was ferritic stainless steel. Yong et al. [20] studied FSW
analysis was also employed using Cu–K α irradiation.
of aluminum to magnesium and reported similar type of band-
The friction stir welding (FSW) joint was characterized
ed structure having alternate layer of aluminum and
in respect of hardness and tensile properties. The
magnesium.
Vickers hardness of the weld was measured at the line
in the middle of the transverse section with 1.96 N load
and dwell time of 10 s. ASTM E-8 guidelines were 3.2 Microstructure and phase analysis
followed to prepare the transverse and longitudinal (all
weld) tensile test specimens [19]. The tensile testing was The microstructural study of FSW joint produced between
performed by using a universal testing machine (Make: structural steel and ferritic stainless steel revealed six dis-
Instron USA; model-5980) of capacity 100 kN, at room tinct regions including both the base metals: I (base metal
temperature and at a crosshead speed of 1 mm/min. The of structural steel), II (HAZ in the structural steel), III (SZ

Fig. 4 Cross-sectional
macrograph of FSW joint
1302
Fig. 5 Microstructure of the
structural steel base metal: a
optical and b SEM micrograph
Fig. 6 OM and SEM micrographs of retreating side: a HAZ and b stir
zone
in the structural steel), IV (SZ in the ferritic stainless
steel), V (HAZ in the ferritic stainless steel), and VI (base
metal of ferritic stainless steel). While going from the
retreating side to advancing side, the first region is the
base metal of structural steel. Figure 5 shows the optical
and SEM micrograph of the structural steel base metal
exhibited equiaxed ferritic grains besides some amount
of fine pearlite. The ferritic grains correspond to the light
Fig. 7 Optical micrographs
showing interfaces in the stir zone
of the weld at various points
Int J Adv Manuf Technol (2017) 88:1299–1307
etching response, whereas the black ones are the pearlite
colonies. The average grain size of equiaxed ferritic
grains was approximately 37 μm as measured by the line
intercept method. The next region is the HAZ on structur-
al steel side (Fig. 6a). The HAZ on structural steel side is
of 1.1 mm which is lower than the normally obtained
HAZ width in case of fusion weld joints (2–4.5 mm)
[21]. The narrow HAZ width is because of lower heat
input associated with the FSW process, but it was high
enough to cause recrystallization of grains and grain
growth. The average size of ferritic grains in this zone
was approximately 22 μm and the pearlite/ferrite ratio
was much higher than the base metal. The grain refine-
ment in the HAZ of structural steel side (22 μm) is attrib-
uted to heating of HAZ region up to inter critical temper-
ature range. This zone is heated well above the effective
A3 temperature resulting in austenite grin growth, which
further transform to ferrite and pearlite upon cooling. No
distinct thermo-mechanical-affected zone was found in
structural steel-ferritic stainless steel joint developed by
FSW. The microstructure of the stir zone on structural
steel side exhibited fine ferrite, pearlite and martensite
grains (Fig. 6b). The stir zone experiences both the ther-
mal and mechanical cycles. The temperature of the stir
zone exceeded 1100 °C [17]; at this temperature, the
structural steel is austenitic having FCC structure.
Further, the stir zone is subjected to the greatest strain
and strain rate with the highest temperature. Under these
conditions, several restoration processes operated during
Int J Adv Manuf Technol (2017) 88:1299–1307 1303

Fig. 8 a SEM micrograph at the

joint interface. b EDX area
analysis of ferritic stainless steel. c
EDX area analysis of structural
steel. d EDX line scan results at
the interface

Fig. 9 a SEM micrograph at the

interface and elemental EDX
mapping: b Fe, c Cr, d Mn, and e
Si
1304 Int J Adv Manuf Technol (2017) 88:1299–1307

Fig. 10 OM and SEM micrographs of advancing side: a stir zone and b

HAZ

friction stir welding in the stir zone including dynamic

recovery and recrystallization [22]. The dynamic recrys-
tallization may also be defined as occurring discontinu-
ously or continuously. The discontinuous dynamic recrys-
tallization is characterized by the nucleation of new grains
at the old high-angle grain boundaries. The stacking fault
energy and the strain rate defines the operative mecha-
nism during process. The material having low stacking
fault energy generally undergoes discontinuous dynamic
Fig. 11 XRD patterns of HAZ and stir zone in FSW joint
recrystallization (DDRX). Moreover, the structural steel
has low stacking fault energy (SFE) in the austenitic
phase field and generally undergoes DDRX [22]. Thus,
the material of the stir zone is expected to undergo was also done for both steels near the interface
DDRX. The aluminum and its alloys normally do not (Fig. 8b, c). Concentration profiles for the dissimilar fric-
undergo DDRX because of their high rate of recovery tion stir-welded specimen of the major elements (Fe, Cr,
due to high stacking fault energy of aluminum alloys Si, and Mn) across the interface are exhibited in Fig. 8d.
[17]. Due to this recrystallization, small austenitic grains EDX elemental mapping for these elements (Fe, Cr, Si,
are produced and results in two different types of micro- and Mn) was also done at the joint interface and are rep-
structure named ferrite and pearlite. A small fraction of resented in Fig. 9. The next zone is the stir zone of ferritic
martensite was also formed at a relatively higher cooling stainless steel, characterized by the presence of highly
rate. In the middle of the stir zone, the interface exists. refined equiaxed ferritic grains with a little amount of
Each base metal had a response to a special etchant. At grain boundary martensite (Fig. 10a). As discussed earlier,
some points, the interface had a sharp boundary, whereas the material close to the tool pin in the stir zone is sub-
at some points, the metals were mixed to some extent jected to the greatest strain and strain rate with the highest
(Fig. 7). The SEM image of the interface is shown in temperature, resulting in refinement in the stir zone. The
Fig. 8a. Energy-dispersive x-ray (EDX) area analysis next zone is the HAZ of ferritic stainless steel; similar to
Int J Adv Manuf Technol (2017) 88:1299–1307
Fig. 12 Microstructure of the
ferritic stainless steel base metal:
a Optical and b SEM micrograph
the HAZ of structural steel this zone, was also narrow in
size and consists of recrystallized ferritic grains of aver-
age size 20 μm (Fig. 10b). The formation of these phases
in stir zone and HAZ of both sides was also confirmed by
x-ray diffraction analysis. XRD peaks suggest the pres-
ence of ferrite and a small fraction of martensite in the
stir zone (Fig. 11). The base metal of ferritic stainless
steel exhibits ferrite grains of average size 23 μm as mea-
sured by the line intercept method besides a little amount
of randomly distributed carbides (Fig. 12).
3.3 Mechanical properties
In order to study the mechanical properties of the weld joint,
micro-hardness and tensile testing were carried out. Vickers
micro-hardness was measured at the middle of the transverse
section of the weld joint at about 1.5 mm below the surface and
at a regular interval of 1 mm (Fig. 13). Starting from retreating
Fig. 13 Hardness profile at the mid thickness of the transverse section of
FSW joint
1305
side (structural steel) towards the advancing side (ferritic stain-
less steel), the first zone is the base of structural steel having
average hardness approximately 140 HV. This zone has the
lowest hardness on micro-hardness profile, i.e., it is the weakest
part of the joint. Due to partial grain refinement, the hardness of
HAZ on the structural steel side increased slightly to 170 HV.
The hardness of the stir zone was found in a range from 186 to
572 HV depending on the material and phase on each indenta-
tion because the stir zone has two different steels. As discussed
earlier, the stir zone consists of fine ferrite, pearlite, and mar-
tensite phases. The localized presence of martensite in the stir
zone is expected to produce a higher hardness than ferrite and
pearlite in the stir zone. The next zone was the HAZ of ferritic
stainless steel consisted ferritic grains. As discussed earlier, this
zone was narrow in size and its hardness was more than the
FSS base and HAZ of structural steel due to the formation of
grain boundary martensite as evident from XRD results. The
last part was the base metal of FSS having large ferritic grains
compared with the stir zone and its hardness was about 225 HV.
The tensile properties of the welded samples as well as base
metals were evaluated and summarized in Table 3. The ulti-
mate tensile strength and yield strength of the weld sample
taken from transverse direction was higher than the structural
steel base metal, whereas lower than the ferritic stainless steel
base metal. Fracture in transverse weld samples took place
from the structural steel base metal because this was the
weakest part of the joint. On the basis of ultimate tensile
strength, the weld efficiency was calculated, which is defined
as the ratio of the strength of the welded structure to the
strength of the base material [23]. In this study, the strength
of structural steel base material was less than the ferritic stain-
less steel base metal so it was used for the calculation of weld
efficiency and it was found to be 117 %. The elongation of the
transverse weld sample was lower than both base metals. The
strength of the longitudinal samples was much higher than the
transverse weld sample due to the presence of a refined grain
structure and a little fraction of martensite in the stir zone. The
1306 Int J Adv Manuf Technol (2017) 88:1299–1307

Table 3 Tensile properties of welded specimens and base metals

Tensile property Tensile strength Yield strength % Weld

(MPa) (MPa) Elongation efficiency
Joint type to failure %

MS 404.5 268.3 26.8 -

Base metal (3.25) (2.70) (0.93)
FSS 508.5 364.6 17.99 -
(3.66) (2.20) (2.12)
Transverse orientation 475.1 330.8 8.71 117
(2.25) (1.51) (0.24)
Longitudinal orientation 1026.0 287.4 4.61 -

Values given in the brackets are standard deviation of the experimental results

strength of longitudinal GTAW joint of low carbon steel and
ferritic stainless steel was reported as 922 and 662 MP1a for
autogenous and ER309L filler, respectively [1]. However, the
percentage elongation of the GTAW joint was 10.36 and 11.33
for autogenous and ER309L filler, respectively. Thus, the
measured strength of the FSW joint was found to be higher
and percentage elongation was lower than the GTAW joint.
Figure 14 shows the stress-strain behavior of both transverse
and longitudinal weld samples.
3.4 SEM study of fracture surfaces
The fractured surface of the tensile specimen was examined
under SEM to study the mode of fracture. Factrographs of the
fractured transverse and longitudinal tensile test specimen of
friction stir-welded joint are shown in Fig. 15. In transverse
samples, the fracture took place in the base metal region show-
ing large and deep dimples. The fracture surface of longitudi-
nal samples shows both very fine shallow dimples as well as
some cleavage planes suggesting the occurrence of combined
mode of fracture with both ductile as well as brittle fracture.
The stir zone is the mixed region of both the steels having a
little amount of martensite due to which the fractured surface
shows both the dimples and the cleavage planes.

4 Conclusion

1. Defect-free welds of structural steel and ferritic stainless

steel plates of thickness 3 mm was produced successfully by
friction stir welding at 508 rpm rotational and 20 mm/min
Fig. 14 Stress vs. strain curve for friction stir-welded dissimilar joint traverse speed.
Int J Adv Manuf Technol (2017) 88:1299–1307
Fig. 15 Fractured surface of: a
transverse and b longitudinal
tensile test specimens
2. Six distinct regions were found in the weld joint including
base metals itself. The stir zone of structural steel was character-
ized by the presence of fine ferrite, pearlite, and martensite grains
whereas highly refined equiaxed ferritic grains with a little frac-
tion of martensite were found in ferritic stainless steel side.
3. The hardness of the stir zone varies from 186 to 572 HV
depending on the material and phase present on each
indentation.
4. The tensile strength of the transverse weld specimen
(475.1 MPa) was higher than the structural steel base metal
(404.5 MPa) but lower than the ferritic stainless steel base
metal (508.5 MPa).
5. The fracture in the transverse welds sample took place from
structural steel base metal because this is the weakest part of
the weld having the lowest hardness value on the micro-
hardness plot. The tensile strength of the longitudinal welds
sample (1026.0 MPa) of the FSW joint was found to be much
higher than both base metals.
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