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.