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<p>Joining commercially pure tungsten (W) to medium-carbon steel (EN8) is difficult because of W’s exceptionally high melting temperature, limited ductility, and tendency to produce brittle intermetallic compounds (IMCs) during conventional fusion welding. In this study, rotary friction welding (RFW) was used to create dissimilar connections between EN8 medium-carbon steel and W, with and without a pure copper interlayer. The study analyzed the microstructural properties of the welded interface, identified potential intermetallic phases, and assessed the mechanical performance of the joints. The addition of a 0.5-mm-thick copper interlayer significantly increased the tensile strength of the W–EN8 connection, raising it from 216 to 598&#xa0;MPa. Microstructural analysis revealed improved metallurgical bonding and lower brittleness, including a continuous defect-free interface with a diffusion-controlled transition layer. These findings demonstrate that attaching W to medium-carbon steel using RFW and an optimized Cu interlayer is a successful strategy for improving joint strength in high-performance industrial applications.</p>

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Interlayer-Mediated Rotary Friction Welding of Pure Tungsten and EN8 Steel: Process–Microstructure–Property Relationships

  • 期刊论文

  • 发表日期：

    2026年7月6日

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  • D. K. Nannaware,
  • V. S. Gadakh

摘要

Joining commercially pure tungsten (W) to medium-carbon steel (EN8) is difficult because of W’s exceptionally high melting temperature, limited ductility, and tendency to produce brittle intermetallic compounds (IMCs) during conventional fusion welding. In this study, rotary friction welding (RFW) was used to create dissimilar connections between EN8 medium-carbon steel and W, with and without a pure copper interlayer. The study analyzed the microstructural properties of the welded interface, identified potential intermetallic phases, and assessed the mechanical performance of the joints. The addition of a 0.5-mm-thick copper interlayer significantly increased the tensile strength of the W–EN8 connection, raising it from 216 to 598 MPa. Microstructural analysis revealed improved metallurgical bonding and lower brittleness, including a continuous defect-free interface with a diffusion-controlled transition layer. These findings demonstrate that attaching W to medium-carbon steel using RFW and an optimized Cu interlayer is a successful strategy for improving joint strength in high-performance industrial applications.