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<p>Friction welding of tube to tube plate using an external tool (FWTPET) is an innovative solid-state joining method for dissimilar materials. This research examines the effect of process parameters on welding a commercially pure titanium (Cp-Ti) tube to a stainless steel (SS304L) tube plate with an aluminium interlayer. The aluminium interlayer was incorporated to improve joint integrity and reduce the formation of brittle intermetallic compounds at the interface. Critical process parameters were evaluated, including plunge rate, rotational speed, plunge depth, axial load, and flash trap profile. Experimental trials were conducted by varying the rotational speed while maintaining other parameters constant. Macrostructural and microstructural evaluations revealed defect-free weld interfaces under all conditions, with the aluminium interlayer disappearing at higher rotational speeds due to increased frictional heat. SEM-EDS analysis confirmed the presence of Ti-Al, Al-Fe, and Ti-Fe phases, while XRD analysis identified intermetallics. Microhardness measurements across the weld interface indicated a hardness drop at the centre. A novel shear test method was developed to assess joint strength, revealing a maximum shear fracture load of 16.64 kN at 700&#xa0;rpm. These findings provide insights into optimizing FWTPET parameters for improved mechanical performance in dissimilar metal welding applications.</p>

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Influence of process variables on dissimilar welding of titanium tube to stainless steel tube plate using an aluminium interlayer via a novel friction external tool process

  • 期刊论文

  • 发表日期：

    2026年4月18日

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  • Maxwell Rejil,
  • Muthu Kumaran,
  • Mutyala Jacob Santosh,
  • Nagaraj Murugan

摘要

Friction welding of tube to tube plate using an external tool (FWTPET) is an innovative solid-state joining method for dissimilar materials. This research examines the effect of process parameters on welding a commercially pure titanium (Cp-Ti) tube to a stainless steel (SS304L) tube plate with an aluminium interlayer. The aluminium interlayer was incorporated to improve joint integrity and reduce the formation of brittle intermetallic compounds at the interface. Critical process parameters were evaluated, including plunge rate, rotational speed, plunge depth, axial load, and flash trap profile. Experimental trials were conducted by varying the rotational speed while maintaining other parameters constant. Macrostructural and microstructural evaluations revealed defect-free weld interfaces under all conditions, with the aluminium interlayer disappearing at higher rotational speeds due to increased frictional heat. SEM-EDS analysis confirmed the presence of Ti-Al, Al-Fe, and Ti-Fe phases, while XRD analysis identified intermetallics. Microhardness measurements across the weld interface indicated a hardness drop at the centre. A novel shear test method was developed to assess joint strength, revealing a maximum shear fracture load of 16.64 kN at 700 rpm. These findings provide insights into optimizing FWTPET parameters for improved mechanical performance in dissimilar metal welding applications.