Materials

& Design
Materials and Design 28 (2007) 2244–2250
www.elsevier.com/locate/matdes

Short communication

Evaluation of the joint-interface properties of austenitic-stainless

steels (AISI 304) joined by friction welding
Mumin Sahin *

Department of Mechanical Engineering, Faculty of Engineering and Architecture, Trakya University, 22030 Edirne, Turkey

Received 13 September 2005; accepted 30 May 2006

Available online 28 July 2006

Abstract

The aim of this study is to investigate experimentally the micro-structural properties and welding strengths of the joints using austen-
itic-stainless steel (AISI 304) parts. The experiments were carried out using a beforehand designed and constructed experimental friction
welding set-up, constructed as continuous-drive. Firstly, pilot welding experiments under different friction time and friction pressure were
carried out to obtain optimum parameters using statistical approach. Later, the strengths of the joints were determined by tension, fati-
gue and notch-impact tests, and results were compared with strengths of materials. Hardness variations and microstructures in the inter-
faces of the joints were also obtained and examined. Then, obtained results were compared with those of previous studies.
 2006 Elsevier Ltd. All rights reserved.

1. Introduction while the axial pressure is being increased to a higher pre-

Friction welding method has extensively been used in
manufacturing methods because of the advantages such as
high material saving, low production time and possibility
of the welding of parts for a long time. In the process, heat
is generated by conversion of mechanical energy into ther-
mal energy at the interfaces of the components during rota-
tion under pressure without any energy from environment.
Friction time, friction pressure, upset time, upset pres-
sure and rotation speed are the most important parameters
in friction welding. The parameters are selected properly in
the experiments since these directly affect welding quality.
Generally, the friction welding methods can be examined
in two types as continuous-drive and inertia welding.
In continuous-drive method, one of the components is
rotated at constant speed (s), while the other is pushed
toward the rotated part by a sliding action under a prede-
termined pressure – friction pressure (Pf). Friction pressure
(Pf) is applied for a certain friction time (tf). Then, the drive
is released and the rotary component is quickly stopped
*
Tel.: +90 284 2251395; fax: +90 284 2126067.
E-mail address: mumins@trakya.edu.tr.
determined upset pressure (Pu) for a predetermined time
(tu). Parameters of the welding method are shown in
Fig. 1 [12,15,16].
Stainless steels are iron-base alloys containing 8–25%
nickel and more chromium than the 12% necessary to pro-
duce passivity but less than 30%. The steels resist both cor-
rosion and high temperature. Stainless steels can be divided
into three types as martensitic, ferritic and austenitic.
Austenitic-stainless steel is preferred more than other stain-
less-steel types due to easiness in welding process. Then,
some negative metallurgic changes are taken into consider-
ation in welding of the steels. These are given as
 delta ferrite phase
 sigma phase
 stress-corrosion cracking
 chrome–carbide precipitate between grain boundaries at
450–850 C of Cr–Ni austenitic steels such as 18/8 joined
by fusion welding in long-waiting time.
But, friction welding method eliminates negative metal-
lurgic changes because of short time and rapid cooling in
working [1].

0261-3069/$ - see front matter  2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2006.05.031
 M. Sahin / Materials and Design 28 (2007) 2244–2250
Friction Time (tf)
Braking
Waiting Upset (tu)
Upset Pressure (Pu)
Rotation Speed (s)
Friction Pressure (Pf)
Torque (T)
Starting Shortening
Time
Fig. 1. Parameters on continuous-drive friction welding.
Various researchers carried out different studies about
friction welding:
The friction welding method was investigated in 1960s
by Vill and Tylecote [2,3]. Later, Jenning [4] and Lucas
[5] investigated the properties of the dissimilar materials
welded by friction welding and the process parameters on
friction welding method in 1970s. And, Ellis [6] examined
the relationship between ‘‘friction time-workpiece diame-
ter’’, ‘‘shortening–upsetting pressure’’ and ‘‘carbon equiva-
lent-hardness variation’’. Murti and Sundaresan [7] carried
out parameter optimisation on friction welding of dissimi-
lar materials. Dunkerton [8] investigated the effects of rota-
tion speed, friction pressure and upsetting pressure in
friction welding methods for steel. Mortensen et al. [9]
investigated mechanical properties and microstructures of
416 stainless steel, resulfurized steel, by inertia friction
welding method.
Then, Sahin and Akata [10] made a study on joining
with friction welding of stainless steels. Akata and Sahin
[11] made investigation on the effect of dimensional differ-
ences in friction welding of AISI 1040 specimens. They
obtained optimum parameters for AISI 1040 specimens.
Sahin and Akata [12] investigated joining of friction weld-
ing with plastically deformed carburizing steel. They exam-
ined effects of plastically deformed on the joints. Same
authors [13] also made article titled an experimental study
on friction welding of medium-carbon and austenitic-stain-
less steel components.
Later, Sahin [14] directed simulation of friction welding
using a developed computer program. Joining of austenitic-
stainless steels with friction welding was carried out by
same author [15]. Sahin [16] made joining with friction
welding of high-speed steel and medium-carbon steel.
And, Özdemir et al. [17] directed effect of rotational speed
on the interface properties of friction-welded AISI 304L to
4340 steel. It is observed that the tensile strength increases
with increase of rotational speed by the authors.
In the presented study, the welding strengths and metal-
lurgic properties of the joints were investigated using
austenitic-stainless steel (AISI 304).
2245
2. Experimental set-up and material
The friction welding set-up designed and constructed beforehand for
experiments was used in the experiments. The set-up is schematically
shown in Fig. 2 [16].
AISI 304 austenitic-stainless steel parts were used in the friction weld-
ing experiments. The chemical compositions and measured tensile
strengths of the test materials are given in Table 1 [18]. Friction welding
experiment of parts are schematically shown in Fig. 3.
3. Determination of parameters using statistical approach
Finishing When a statistician suggests the experimental runs to be
made in a series of tests, data analysis can be quite straight-
forward. However, often, an analysis must be carried out
on results that have been accumulated as part of a test pro-
gram or as a series of related test programs and an empir-
ical predictive model must be constructed from the results
obtained. Terms for possible inclusion in the model might
involve not only the principal variables but also variables
such as cross products, squares, or other combinations,
or transformations, of the principal variables [19].
The basis of this approach is the assumption of a simpli-
fied linear model for the optimisation parameter g given by
g = b0 + b1x1 + b2x2 + . . ., where x1, x2, . . ., are the factors
on which g depends and b0, b1, b2, . . ., represent the ‘true’
values of the corresponding unknowns. From the results
of an experiment comprising a finite number of trials,
one can arrive at sample estimates of the coefficients, b,
which are then usually fitted into a linear regression equa-
tion of the type y = b0 + b1x1 + b2x2 + . . ., where y is the
response function and the bs are the ‘estimated’ values of
the bs. In simple terms, each coefficient represents the influ-
ence of the corresponding factor on the quality of the weld
expressed by the optimisation parameter.
Workpieces Hydraulic
Guide Group
1
Chuck Clamp
2
Clutch Bearings
3
Control of P T
Drive Friction
Pressure
M: Motor
P: Setting of Pressure
T: Exit of Pressure Control of
1: Valve Upset P T
2: Indicator Pressure
3: Solenoid Valve
M
Oil Tank
Fig. 2. Continuous-drive friction welding set-up.
2246 M. Sahin / Materials and Design 28 (2007) 2244–2250

Table 1
The chemical composition of the material used in the experiments
Material %C %P %S %Mn %Si %Cr %Ni Tensile strength (MPa)
AISI 304 (X5CrNi1810) <0.07 <0.045 <0.030 <2.0 <1.0 17–19 8.5–10.5 825

AISI 304 AISI 304 Later, parameters having the least error using the
(d1 = 10mm) (d2 = 10mm)
s (rpm) method of least squares were taken as the optimum welding
parameters. The optimum welding conditions are given
Ps (MPa), ts (sec.) Table 3.
As a result, the optimum parameters were found as fol-
lows. Friction time = 9 s, friction pressure = 60 MPa,
Lathe Chuck
upset time = 20 s and upset pressure = 110 MPa.
Later, the strengths and metallurgic properties of
Fig. 3. Parts used in the experiments. obtained joints were investigated and the results were com-
pared with those of fully machined ones [15].

The statistical analysis involves two steps: first, the 4. The experimental results and discussion
adequacy of the model is tested. A suitable method is
based on the Fischer or ‘F’ ratio, which can be used to 4.1. The tensile tests
confirm if the terms in the assumed linear function are
statistically significant. The second step is to obtain opti- The effects of friction time and friction pressure on the
mal estimates of the regression coefficients for the signif- strength of the joints were investigated in welding of parts.
icant factors, which may be done using the method of Welding experiments keeping the upset time and upset
least squares [7]. pressure [20] constant were directed to obtain proper fric-
Parameter optimisation was carried out using factorial tion time and friction pressure. Firstly, while friction pres-
design of experiments. The two factors chosen were friction sure (60 MPa) was kept constant, friction times were
time and friction pressure. The other parameters such as changed. Secondly, while friction time (9 s) was kept con-
upset time, upset pressure and rotational speed were main- stant, friction pressures were changed.
tained constant. Experimental results for factors are given The tensile strengths of the welded joints were calculated
in Table 2. First, optimal estimates of regression coeffi- by dividing the ultimate loads by area of 10 mm diameter,
cients were obtained using the method of Fisher ratio. Pre- and the results were compared with those of fully machined
diction equation is also given below: ones.
Relations between the tensile strength versus the friction
y ¼ 581; 696 þ 15; 465x1 þ 46; 226x2 ð1Þ time and the friction pressure are shown graphically in
The correlation coefficient using Eq. (1) is about 0.90 in Figs. 4 and 5 [15].
respect of tensile strength. Therefore, it is quantitatively The tensile strengths of the joints increase as the friction
shown that the effects of friction time and friction pressure time and friction pressure for the joints are increased as
on the tensile strength are very significant as expected. shown in Figs. 4 and 5.
But, the strength of the joints raises a maximum, and
later, the tensile strength of the joints decreases when the
friction time and pressure for the joints are increased.
Table 2 Because, when the friction time and friction pressure of
Experimental results for factors the joints are increased more than optimum parameters,
Trial No. Friction Friction Tensile strength (MPa) parts heat and deform much more. Therefore, the strength
pressure (MPa) x1 time (s) x2 of joints decreases.
1 20 9 80 The maximum tensile strength values of the joints are
2 45 9 700 also harmonious with those obtained optimum parameters
3 60 9 795.8 using statistical approach.
4 60 3 450 Then, obtained maximum strength in the joints has
5 60 11 750
about 96% that of base austenitic-stainless steel parts.

Table 3
Optimum welding conditions
Metal Friction pressure (MPa) Friction time (s) Upset pressure (MPa) Upset time (s) Rotational speed (rpm)
Austenitic-stainless steel 60 9 110 20 1440
 M. Sahin / Materials and Design 28 (2007) 2244–2250 2247

Austenitic-Stainless Steel Austenitic-Stainless Steel

d1=10mm. and d2=10mm. d1=10mm. and d2=10mm.
(Pf=60MPa., Pu=110MPa., tu=20sec.) (tf=9sec., Pu=110 MPa., tu=20sec.)
Tensile Strength= 825MPa.
Tensile Strength=825MPa.

850 850

800 800
750
750
700
700
650
650
600

Tensile Strength (MPa.)

600
Tensile Strength (MPa.)

550
550
500
500
450
450
400
400
350
350
300
300
250
250
200
200
150
150
100
100
50
50
0
0
0 15 30 45 60 75 90
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Friction pressure (Pf) MPa.
Friction time (tf) sec.
Fig. 5. Relationship between tensile strength versus friction pressure.
Fig. 4. Relationship between tensile strength versus friction time.

Ø5
4.2. The fatigue tests

The fatigue tests were made in Instron 8501 machine.

During the tests the load application frequency was 10 25 10 Ø 10

20 Hz. Some of welded parts were exposed the fatigue tests 55

under axially tension. The geometry of parts to be tested is
given in Fig. 6.
The fatigue properties of machined AISI 304 parts at
first, and AISI 304 to AISI 304 joints at last were investi-
gated, respectively. In the experiments, fatigue tests were
conducted as superimposing some fluctuating tensile loads
on a constant tensile load. Constant tensile load was deter-
mined to produce 300 MPa tensile stresses. Fluctuating
tensile stress amplitudes were changed between 150 MPa
and 250 MPa as shown in Fig. 7, and numbers of cycles
to fracture were recorded. Also, the fatigue results of the
welded parts were compared with those of the machined
base parts. The relations are shown in Fig. 7.
The fatigue strengths of welded parts as shown in Fig. 7
are slightly lower than those of AISI 304 parts.
4.3. The notch-impact tests
Some of welded parts and machined base parts were
exposed to the notch-impact tests with the charpy method,
machining of a notch at the interface. The geometry of
Fig. 6. The geometry of the fatigue test part exposed axially tension.
parts to be tested is given in Fig. 8. Firstly, the fracture
energy values were investigated for machined AISI 1040
parts. Later, the notch-impact tests of welded parts were
investigated. And, the fracture energy results of the welded
parts were compared with those of the machined base
parts. Because of differences in dimensions of specimen,
energy absorbed in Charpy-V notch-impact test for each
specimen was divided with its net area according to DIN
50115. Calculated notch-impact toughness according to
above procedure is given in Table 4.
The notch-impact toughness of welded parts as shown in
Table 4 is nearly twice as those of AISI 304 parts.
4.4. Microstructure of welded parts
Macro-photo of joint after etched in picral is shown in
Fig. 9. Microstructure-photos in the parent metals,
2248 M. Sahin / Materials and Design 28 (2007) 2244–2250

The Fatigue Results of Welded and Base Parts

Welded Parts AISI 304 Parts

400

350

Stress Amplitude (MPa) 300

250

200

150

100

50

0
1000 10000 100000 1000000

Number of Cycles for Failure (Log N)

Fig. 7. The fatigue test results.

45˚
2
10

55 10

Fig. 8. The charpy notch-impact part (left). Section through notch (right).

heat-affected zone (HAZ) and interface region of the joints

after etched in picral are shown in Figs. 10–12.
Fig. 9 shows the central axial-section of welded joints
with representative shape of burr. The burr that is pro-
duced in the equal steel joints is identical to both stainless
steel sides as seen from Fig. 9.
Then, it is shown that the microstructures taken from
the base material, HAZ and welding metal of joint have
Fig. 9. Macro-photograph of joint, as welded.
homogeneous-austenitic structure.

4.5. Hardness variations of welded parts

Hardness variations obtained by Vickers hardness test- and the vertical direction of welded parts are shown in
ing and measuring locations on the horizontal direction Figs. 13 and 14.
Fig. 13 shows the hardness variations on the horizontal
distances in obtained austenitic-stainless steel joints using
Table 4 friction welding. The hardness of the joints is decreased
The notch-impact test results at interface zone of joint as seen in Fig. 13. These are
Material Notch-impact due to the fact that the AISI 304 steel is not a hardenable
toughness (J/cm2) one by heat treatment. Then, there is a slight decrease
AISI 304 (Machining specimens) @181.25 towards side of parts on the vertical distance of the joints
Welded joint specimens (AISI 304 – AISI 304) @400.60 as seen in Fig. 14.
 M. Sahin / Materials and Design 28 (2007) 2244–2250 2249

Austenitic-Stainless Steel (AISI 304)

d1=10mm. and d2=10mm.
750
700
650
600

Vickers Hardness (HV)

550
Horizontal
500
450 Distance
Weld-Centre 400
350
300
250
200
150
100
50
0
-5 -4 -3 -2 -1 0 1 2 3 4 5
Fig. 10. Microstructure of AISI 304 steel.
Horizontal Distance (mm.)

Fig. 13. Hardness variations on horizontal distance.

Austenitic-Stainless Steel (AISI 304)

d1=10mm. and d2=10mm.
750
700 Vertical
Distance
650
600
Vickers Hardness (HV)

550
500
450
Weld-Centre
400
350
300
250
200
150
100

Fig. 11. Microstructure of HAZ on the welded joints, as welded. 50

0
0 1 2 3 4 5
Vertical Distance (mm)

Fig. 14. Hardness variations on vertical distance.

5. Conclusions

 Continuous-drive friction welding method can success-

fully be adopted for production of austenitic-stainless
steels (AISI 304).
 Optimum welding parameters should be properly
selected in friction welding of steels.
 Statistical analysis is an economical and reliable method
for optimising welding parameters.
 The tensile strength of the joints increases together with
the friction time and pressure, and it raises a maximum,
but it decreases for more friction time and pressure.
Then, obtained maximum strength in the joints has
Fig. 12. Microphotograph of weld interface, as welded [15]. about 96% that of base austenitic-stainless steel parts.
2250 M. Sahin / Materials and Design 28 (2007) 2244–2250
 The fatigue strength of the welded joints shows similar
behavior like the tensile properties. Thus, it can be con-
cluded that welded parts are suitable for machine ele-
ments operated under dynamic loads. The fatigue
strengths of welded parts are close to those of AISI
304 parts, base metal.
 The notch-impact toughness is about twice as that of
AISI 304 parts, base metal. As a result, welded parts
can easily resist against both static and dynamic loads.
 As it is observed from the hardness variations and micro-
structures, AISI 304 austenitic-stainless steel has no con-
siderable hardening effect in the welding zone of joints.
Acknowledgements
Author thanks Prof. Dr. H. Erol AKATA, Trakya Uni-
versity/Edirne – Turkey, for his advice and help. And,
author also thanks to Trakya University/Edirne – Turkey
and Hema Industry/Çerkezköy – Turkey for the helps in
experimental part of the study.
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