Effect of friction welding parameters on the tensile strength and microstructural properties of dissimilar AISI 1020-ASTM A536 joints

This paper presents an effect of friction welding parameters on the tensile strength and microstructural properties of dissimilar AISI 1020-ASTM A536 joints. A hybrid response surface methodology (RSM) and genetic algorithm (GA)-based technique were successfully developed to model, simulate, and optimise the welding parameters. Direct and interaction effects of process parameters on the ultimate tensile strength (UTS) were studied by plotting graphs. Friction force and friction time have a positive effect on tensile strength. As friction force and friction time increase, the tensile strength also increases. The maximum tensile strength of the friction-welded low carbon steel-ductile iron joints was 87 % of that of the base metal. The tensile properties, microstructure, Vickers hardness distribution, and fracture morphology of the welded specimen have been studied and presented in this study. Additionally, the distribution of carbon element on both sides of the interface was estimated using energy-dispersive spectroscopy (EDS). The results of the metallographic study show clearly that the friction welding process was accompanied by a diffusion of carbon atoms from ductile iron to steel. This process causes the formation of a carbon-rich zone at the interface and decarburization zone in the ductile iron close to the bond interface.