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<p>This study presents a comprehensive experimental investigation into the influence of rotary friction-welding parameters on the mechanical integrity, microstructural evolution, and phase stability of similar AISI 304 austenitic stainless-steel joints. A Taguchi L27 orthogonal array involving 27 experimental trials was employed to systematically evaluate the combined effects of rotational speed (800 to 1200&#xa0;rpm), friction pressure (20 to 60&#xa0;MPa), forging pressure (20 to 60&#xa0;MPa), friction time (2 to 6&#xa0;s), and forging time (2 to 6&#xa0;s). Mechanical performance was assessed through ultimate tensile strength and elongation, while Vickers microhardness mapping was carried out symmetrically across both sides of the weld interface, covering the base metal and thermomechanically affected zones. Microstructural evolution and fracture behavior were examined using optical microscopy and scanning electron microscopy, and phase stability and process-induced residual strain were analyzed by X-ray diffraction.The results demonstrate that an optimized parameter combination of 1000&#xa0;rpm rotational speed, 40&#xa0;MPa friction pressure, 60&#xa0;MPa forging pressure, and approximately 4&#xa0;s friction and forging times produced defect-free joints with a maximum tensile strength of 568&#xa0;MPa, corresponding to about 90 to 95% of the base metal strength. A symmetrical hardness profile with peak values of 219 to 241 HV at the fully deformed zone was observed, attributed to uniform heat generation, balanced axial deformation despite asymmetric rotation, and dynamic recrystallization. Fractography revealed predominantly ductile fracture with fine, uniformly distributed dimples, while XRD confirmed retention of the austenitic γ-Fe phase without deleterious secondary phases. Overall, the study establishes a robust process window for producing high-integrity AISI 304 friction-welded joints with refined microstructure and stable phase constitution.</p>

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Comprehensive investigation on the influence of friction welding parameters on the mechanical integrity, microstructural evolution, and phase stability of AISI 304 austenitic stainless-steel joints

  • 期刊论文

  • 发表日期：

    2026年1月28日

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  • Arul Moorthy,
  • Dinesh Subbiah,
  • Mathiazhagan Nallusamy,
  • Sureshkumar Myilsamy,
  • Manikandan Durairaj,
  • Krishnaraj Ramaswamy

摘要

This study presents a comprehensive experimental investigation into the influence of rotary friction-welding parameters on the mechanical integrity, microstructural evolution, and phase stability of similar AISI 304 austenitic stainless-steel joints. A Taguchi L27 orthogonal array involving 27 experimental trials was employed to systematically evaluate the combined effects of rotational speed (800 to 1200 rpm), friction pressure (20 to 60 MPa), forging pressure (20 to 60 MPa), friction time (2 to 6 s), and forging time (2 to 6 s). Mechanical performance was assessed through ultimate tensile strength and elongation, while Vickers microhardness mapping was carried out symmetrically across both sides of the weld interface, covering the base metal and thermomechanically affected zones. Microstructural evolution and fracture behavior were examined using optical microscopy and scanning electron microscopy, and phase stability and process-induced residual strain were analyzed by X-ray diffraction.The results demonstrate that an optimized parameter combination of 1000 rpm rotational speed, 40 MPa friction pressure, 60 MPa forging pressure, and approximately 4 s friction and forging times produced defect-free joints with a maximum tensile strength of 568 MPa, corresponding to about 90 to 95% of the base metal strength. A symmetrical hardness profile with peak values of 219 to 241 HV at the fully deformed zone was observed, attributed to uniform heat generation, balanced axial deformation despite asymmetric rotation, and dynamic recrystallization. Fractography revealed predominantly ductile fracture with fine, uniformly distributed dimples, while XRD confirmed retention of the austenitic γ-Fe phase without deleterious secondary phases. Overall, the study establishes a robust process window for producing high-integrity AISI 304 friction-welded joints with refined microstructure and stable phase constitution.