Process Parameter Optimization of Friction Crush Welding (FCW) of AISI 304 Stainless Steel

2017 ◽  
Author(s):  
Gurinder Singh Brar ◽  
Manpreet Singh ◽  
Ajay Singh Jamwal
Keyword(s):  
Stainless Steel ◽  
Friction Stir Welding ◽  
Welding Process ◽  
Pressure Vessels ◽  
304 Stainless Steel ◽  
Welding Parameters ◽  
Work Piece ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304 ◽  
Friction Stir

AISI 304 stainless steel is one of the grades of steel widely used in engineering applications particularly in chemical equipments, food processing, pressure vessels and paper industry. Friction crush welding (FCW) is type of friction welding, where there is a relative motion between the tool and work-piece. In FCW process, the edges of the work-piece to be joined are prepared with flanged edges and then placed against each other. A non-consumable friction disc tool will transverse with a constant feed rate along the edges of the work-piece, which leads to welding. The joint is formed by the action of crushing a certain amount of additional flanged material into the gap formed by the contacting material. The novelty of present work is that FCW removes the limitations of friction stir welding and Steel work pieces can be economically welded by FCW. Taguchi method of Design of Experiments (DOE) is used to find optimal process parameters of Friction Crush Welding (FCW). A L9 Orthogonal Array, Signal to Noise ratio (S/N) and Analysis of Variance are applied to analyze the effect of welding parameters (welding speed, RPM, tool profile) on the weld properties like bond strength. Grain refinement takes place in friction crush welding as is seen in friction stir welding. Friction crush welding process also has added advantage in reducing distortion and residual stresses.

Microstructural characterization and in-process traverse force during friction stir welding of austenitic stainless steel

2019 ◽  
Vol 234 (5) ◽  
pp. 1031-1043
Author(s):  
Arshad Noor Siddiquee ◽  
Sunil Pandey ◽  
Mustufa Haider Abidi ◽  
Abdulrahman Al-Ahmari ◽  
Noor Zaman Khan ◽  
...  
Keyword(s):  
Stainless Steel ◽  
Friction Stir Welding ◽  
Traverse Speed ◽  
304 Stainless Steel ◽  
Welding Parameters ◽  
Aisi 304 Stainless Steel ◽  
Aisi 304 ◽  
Friction Stir ◽  
Tool Shoulder ◽  
Shoulder Diameter

Welding AISI 304 stainless steel is challenging, especially as fusion-based welding processes (such as arc welding) severely undermine the material's corrosion resistance due to sensitization. Solid-state friction stir welding is one of the most suitable alternatives. Friction stir welding of high-strength high-softening materials such as AISI 304 is difficult mainly because of the non-availability of affordable tools and tool life. In this study, AISI 304 stainless steel was successfully butt-welded by friction stir welding. The experiments were performed using Taguchi's L27 orthogonal array. Shoulder diameter, tool r/min, and traverse speed were selected as the most influential welding parameters. A Tungsten Carbide (WC) tool was employed with a tapered pin profile. Defect-free joints were fabricated successfully for all the welding conditions. Microstructural examinations using optical microscopy and scanning electron microscopy revealed significant grain refinement in the stir zone and the presence of distinct structural features such as stepped, dual, and ditch in various characteristics zones. The presence of precipitates was also observed in samples and was confirmed via energy-dispersive X-ray spectroscopy analysis. The in-process traverse force was measured by a special arrangement of force measuring units attached to the work fixture. The traverse force data were analyzed and optimized. The results of an analysis of variance reveal that the traverse speed was the most important parameter, followed by tool r/min, interaction between the tool shoulder diameter and traverse speed, interaction between the tool shoulder diameter and tool r/min, and, finally, the tool r/min.

Effects of Activating Flux on Inconel 718 Alloy and AISI 304 Stainless Steel Dissimilar TIG Welds

2012 ◽  
Vol 626 ◽  
pp. 518-522
Author(s):  
Hsuan Liang Lin ◽  
Zhau Hong Hsu ◽  
Wun Kai Wang
Keyword(s):  
Stainless Steel ◽  
Inconel 718 ◽  
Welding Process ◽  
304 Stainless Steel ◽  
Angular Distortion ◽  
Aisi 304 Stainless Steel ◽  
Inconel 718 Alloy ◽  
Aisi 304 ◽  
Activating Flux ◽  
Dissimilar Welds

The purpose of this work is to investigate the effects of activating flux on the penetration, depth-to-width ratio (DWR), angular distortion and hardness of Inconel 718 alloy and AISI 304 stainless steel (SS) dissimilar welds in the tungsten inert gas (TIG) welding process. In the activated TIG (A-TIG) process, the single component fluxes such as SiO2, NiO, MoO3 and MoS2 and the mixed component fluxes that using 50 % of each single component flux to create six new mixtures were used in the experiment. The experimental results showed that the A-TIG welds coated with 100% SiO2 flux was provided with best DWR of dissimilar welds. In addition, the experimental procedure of A-TIG welding process not only produced a significant increase in penetration and DWR of weld bead, but also improved the angular distortion and hardness of Inconel 718 alloy and AISI 304 SS dissimilar welds.

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