Influence of tool plunging rate on mechanical properties and microstructure of friction stir welded DMR249A high strength low alloy (HSLA) steel butt joints
-
Seerangan Ragu Nathan
Dr. Seerangan Ragu Nathan is working as Associate Professor in the Micromachining Research Centre (MMRC), Department of Mechanical Engineering at Sree Vidyanikethan Engineering College, Tirupati, Andhra Pradesh, India, He has 13 years of work experience in teaching and Research. His research areas are materials joining, corrosion, composites, tribology and additive manufacturing.
,
Visvalingam Balasubramanian
Prof. Visvalingam Balasubramanian is working as Professor & Director of Centre for Materials Joining & Research (CEMAJOR), Department of Manufacturing Engineering at Annamalai University, Chidambaram, Tamil Nadu, India. He has 28 years of teaching and research work experience. His areas of interest are Materials Joining, Surface Engineering and Nanomaterials.
,
Ardula Gourav Rao
Dr. Ardula Gourav Rao is working as Senior Scientist in the DRDO Naval Materials Research Laboratory (NMRL), Ambernath, Maharashtra, India. He has 20 years of research work experience in materials joining technology for defence applications. His areas of interest are materials joining technology and surface engineering.
,
Tushar Sonar
Dr. Tushar Sonar is working as Senior Research Scientist in the Department of Welding Engineering at Institution of Engineering and Technology, South Ural State University, Chelyabinsk, Russia. He has 08 years of work experience including teaching, industry and research. His research interests include welding and joining, additive manufacturing and high entropy alloys.
,
Mikhail Ivanov
Prof. Mikhail Ivanov is working as a Professor and Head of the Department of Welding Engineering at Institution of Engineering and Technology, South Ural State University, Chelyabinsk, Russia. He has total of 17 years of work experience including teaching and research. His research interests include welding and joining, hot tears, cold cracks and simulation of welding phenomena.
and
Chinnasamy Rajendran
Dr. Chinnasamy Rajendran is working as Associate Professor in Department of Mechanical Engineering at Sri Krishna College of Engineering and Technology, Coimbatore, Tamil Nadu, India. He has 20 years of work experience including teaching and research. His research areas are metal joining, corrosion, composite materials, tribology and additive manufacturing.
Abstract
The main aim of this study is to analyse the influence of tool plunging rate on tool wear and stir zone characteristics of DMR249A high strength low alloy (HSLA) steel joints developed using friction stir welding (FSW). The HSLA steel plates were welded at five levels of tool plunging rates varying from 2.0 mm min−1 to 3.0 mm min−1. The tool rotational speed of 600 rpm and welding speed of 30 mm min−1 were kept constant during welding. The wear of FSW tool was analysed by microscopic observations of tool condition after welding, stir zone characteristics, weight loss measurement and pin profile analysis. The characterization techniques of optical microscopy (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were employed to analyse the microstructural characteristics of stir zone of welded joints. Results disclosed that the severe degradation of FSW tool occurred due to the sudden dynamic impact load on tool pin while plunging and more diffusion of work piece material into the tool pin which leads to insufficient plasticized material flow. The tool plunging rate of 2.5 mm min−1 showed minimum tool wear and produced defect free sound joint.
Funding source: DRDO, Naval Material Research Laboratory (NMRL), Ambernath, India
Award Identifier / Grant number: G8/15250/2011 dated 29.02.2012
About the authors
Dr. Seerangan Ragu Nathan is working as Associate Professor in the Micromachining Research Centre (MMRC), Department of Mechanical Engineering at Sree Vidyanikethan Engineering College, Tirupati, Andhra Pradesh, India, He has 13 years of work experience in teaching and Research. His research areas are materials joining, corrosion, composites, tribology and additive manufacturing.
Prof. Visvalingam Balasubramanian is working as Professor & Director of Centre for Materials Joining & Research (CEMAJOR), Department of Manufacturing Engineering at Annamalai University, Chidambaram, Tamil Nadu, India. He has 28 years of teaching and research work experience. His areas of interest are Materials Joining, Surface Engineering and Nanomaterials.
Dr. Ardula Gourav Rao is working as Senior Scientist in the DRDO Naval Materials Research Laboratory (NMRL), Ambernath, Maharashtra, India. He has 20 years of research work experience in materials joining technology for defence applications. His areas of interest are materials joining technology and surface engineering.
Dr. Tushar Sonar is working as Senior Research Scientist in the Department of Welding Engineering at Institution of Engineering and Technology, South Ural State University, Chelyabinsk, Russia. He has 08 years of work experience including teaching, industry and research. His research interests include welding and joining, additive manufacturing and high entropy alloys.
Prof. Mikhail Ivanov is working as a Professor and Head of the Department of Welding Engineering at Institution of Engineering and Technology, South Ural State University, Chelyabinsk, Russia. He has total of 17 years of work experience including teaching and research. His research interests include welding and joining, hot tears, cold cracks and simulation of welding phenomena.
Dr. Chinnasamy Rajendran is working as Associate Professor in Department of Mechanical Engineering at Sri Krishna College of Engineering and Technology, Coimbatore, Tamil Nadu, India. He has 20 years of work experience including teaching and research. His research areas are metal joining, corrosion, composite materials, tribology and additive manufacturing.
Acknowledgement
The authors express thanks to Dr. A. K. Lakshminarayanan, Associate Professor, SSN College of Engineering, Chennai, India for his valuable suggestions, guidance, and discussion to carry out this investigation.
-
Author contributions: All the authors have accepted responsibility for the entire content ofthis submitted manuscript and approved submission.
-
Research funding: The authors are grateful to the Director, Naval Material Research Laboratory (NMRL), Ambernath for the financial support through CARS project No: G8/15250/2011 dated 29.02.2012 and providing base material for this investigation.
-
Conflict of interest: The authors declare no conflicts of interest regarding this article.
References
[1] S. R. Nathan, V. Balasubramanian, S. Malarvizhi, and A. G. Rao, “Effect of welding processes on mechanical and microstructural characteristics of high strength low alloy naval grade steel joints,” Def. Technol., vol. 11, no. 3, pp. 308–317, 2015, https://doi.org/10.1016/j.dt.2015.06.001.Search in Google Scholar
[2] M. Venkatesh Kannan, N. Arivazhagan, M. Nageswara Rao, G. M. Reddy, K. V. Phani Prabhakar, and P. Gadhe, “Studies on microstructure and mechanical properties of weldments produced in 12 mm thick naval grade high strength low alloy steel for sub-zero application by single and double pass hybrid laser arc welding,” J. Mater. Eng. Perform., vol. 31, pp. 3234–3248, 2022, https://doi.org/10.1007/s11665-021-06403-x.Search in Google Scholar
[3] P. Hariprasath, P. Sivaraj, V. Balasubramanian, S. Pilli, and K. Sridhar, “Evaluation of high cycle fatigue behavior of flux cored arc welded naval grade DMR249 A grade steel joints for ship hull structures,” Forces Mech., vol. 11, p. 100189, 2023, https://doi.org/10.1016/j.finmec.2023.100189.Search in Google Scholar
[4] R. Pamnani, M. Vasudevan, P. Vasantharaja, and T. Jayakumar, “Optimization of A-GTAW welding parameters for naval steel (DMR 249 A) by design of experiments approach,” Proc. Inst. Mech. Eng., Part L, vol. 231, no. 3, pp. 320–331, 2017, https://doi.org/10.1177/1464420715596.Search in Google Scholar
[5] P. Hariprasath, P. Sivaraj, V. Balasubramanian, S. Pilli, and K. Sridhar, “Assessment of fatigue life prediction on gas metal arc welded DMR249A steel joints for ship hull structure,” J. Fail. Anal. Prev., vol. 23, pp. 436–448, 2023, https://doi.org/10.1007/s11668-023-01593-z.Search in Google Scholar
[6] R. Pamnani, M. Vasudevan, T. Jayakumar, and P. Vasantharaja, “Development of activated flux, optimization of welding parameters and characterization of weld joint for DMR-249A shipbuilding steel,” Trans. Indian Inst. Met., vol. 70, pp. 49–57, 2017, https://doi.org/10.1007/s12666-016-0857-0.Search in Google Scholar
[7] P. Hariprasath, P. Sivaraj, V. Balasubramanian, S. Pilli, and K. Sridhar, “Effect of the welding technique on mechanical properties and metallurgical characteristics of the naval grade high strength low alloy steel joints produced by SMAW and GMAW,” CIRP J. Manuf. Sci. Technol., vol. 37, pp. 584–595, 2022, https://doi.org/10.1016/j.cirpj.2022.03.007.Search in Google Scholar
[8] P. Hariprasath, P. Sivaraj, V. Balasubramanian, S. Pilli, and K. Sridhar, “Effect of welding processes on high cycle fatigue behavior for naval grade HSLA joints: a fatigue strength prediction,” Eng. Failure Anal., vol. 142, p. 106783, 2022, https://doi.org/10.1016/j.engfailanal.2022.106783.Search in Google Scholar
[9] G. Chakraborty, R. Rejeesh, and S. K. Albert, “Study on hydrogen assisted cracking susceptibility of HSLA steel by implant test,” Def. Technol., vol. 12, no. 6, pp. 490–495, 2016, https://doi.org/10.1016/j.dt.2016.09.003.Search in Google Scholar
[10] S. R. Nathan, V. Balasubramanian, S. Malarvizhi, and A. G. Rao, “An investigation on metallurgical characteristics of tungsten based tool materials used in friction stir welding of naval grade high strength low alloy steels,” Int. J. Refract. Met. Hard Mater., vol. 56, pp. 18–26, 2016, https://doi.org/10.1016/j.ijrmhm.2015.12.005.Search in Google Scholar
[11] TWI, UK, Friction stir welding, 2023. https://www.twi-global.com/technical-knowledge/jobknowledge/friction-stir-welding-147.Search in Google Scholar
[12] P. Parasuraman, T. Sonar, and S. Rajakumar, “Microstructure, tensile properties and fracture toughness of friction stir welded AA7075-T651 aluminium alloy joints,” Mater. Test., vol. 64, no. 12, pp. 1843–1850, 2022, https://doi.org/10.1515/mt-2022-0212.Search in Google Scholar
[13] C. Rajendran, K. Srinivasan, V. Balasubramanian, T. Sonar, and H. Balaji, “Friction stir welding for manufacturing of a light weight combat aircraft structure,” Mater. Test., vol. 64, no. 12, pp. 1782–1795, 2022, https://doi.org/10.1515/mt-2022-0165.Search in Google Scholar
[14] T. Ramakrishna, S. S. Rao, and G. S. Naidu, “Strength and hardness of post-weld heat-treated thick section 7075 Al alloy friction stir welds,” Mater. Test., vol. 61, no. 5, pp. 411–416, 2019, https://doi.org/10.3139/120.111335.Search in Google Scholar
[15] C. Rajendran, K. Srinivasan, V. Balasubramanian, H. Balaji, M. Vinoth Kumar, and S. Ragunathan, “Dynamic recrystallization in friction stir welded AA2014 aluminium alloy joints to replace riveted joints,” Mater. Test., vol. 65, no. 7, pp. 1085–1096, 2023, https://doi.org/10.1515/mt-2022-0351.Search in Google Scholar
[16] B. Çevik, Y. Özçatalbaş, and B. Gülenç, “Effect of tool material on microstructure and mechanical properties in friction stir welding,” Mater. Test., vol. 58, no. 1, pp. 36–42, 2016, https://doi.org/10.3139/120.110816.Search in Google Scholar
[17] T. Rao, G. M. Reddy, and S. R. K. Rao, “Investigation on variations in hardness and microstructure of in-process cooled 7075 aluminum alloy friction stir welds,” Mater. Test., vol. 59, no. 2, pp. 155–160, 2017, https://doi.org/10.3139/120.110977.Search in Google Scholar
[18] M. Ravichandran, M. Thirunavukkarasu, S. Sathish, and V. Anandakrishnan, “Optimization of welding parameters to attain maximum strength in friction stir welded AA7075 joints,” Mater. Test., vol. 58, no. 3, pp. 206–210, 2016, https://doi.org/10.3139/120.110838.Search in Google Scholar
[19] S. Kasman and S. Ozan, “Investigations on microstructural and mechanical properties of friction stir welded AA 2024-T351,” Mater. Test., vol. 62, no. 8, pp. 793–802, 2020, https://doi.org/10.3139/120.111555.Search in Google Scholar
[20] A. Orhan and Y. Asma, “Effect of rotation speed on the quality of friction welded AA 6061/AA 7075 joints,” Mater. Test., vol. 56, no. 5, pp. 381–385, 2014, https://doi.org/10.3139/120.110571.Search in Google Scholar
[21] K. Thamilarasan, S. Rajendraboopathy, G. M. Reddy, T. S. Rao, S. Rama, and K. Rao, “Salt fog corrosion behavior of friction stir welded AA2014-T651 aluminum alloy,” Mater. Test., vol. 58, nos. 11–12, pp. 932–938, 2016, https://doi.org/10.3139/120.110941.Search in Google Scholar
[22] N. Vasudevan, G. B. Bhaskar, T. S. Rao, and M. Mohandass, “Mechanical properties of cryogenically treated AA5083 friction stir welds,” Mater. Test., vol. 61, no. 12, pp. 1129–1134, 2019, https://doi.org/10.3139/120.111430.Search in Google Scholar
[23] P. Prabhuraj, R. Rajakumar, T. Sonar, M. Ivanov, I. Rajkumar, and E. D. Raja, “Effect of retrogression and reaging (RRA) on pitting and stress corrosion cracking (SCC) resistance of stir zone of high strength AA7075-T651 alloy joined by friction stir welding,” Int. J. Lightweight Mater. Manuf., vol. 6, no. 2, pp. 264–277, 2023, https://doi.org/10.1016/j.ijlmm.2022.12.002.Search in Google Scholar
[24] P. Prabhuraj, S. Rajakumar, V. Balasubramanian, T. Sonar, M. Ivanov, and D. Elil Raja, “Effect of pH value, chloride ion concentration and salt spraying time on salt fog corrosion resistance of friction stir welded AA7075-T651 alloy joints,” Int. J. Interact. Des. Manuf., 2023. https://doi.org/10.1007/s12008-023-01415-4, in press.Search in Google Scholar
[25] S. Kalidass, S. Gnanasekaran, A. R. Akilesh, et al.., “Investigation of shoulder diameter to sheet thickness (D/T) ratio on tensile properties friction stir welded AA2014-T6 aluminum alloy joints,” Adv. Mater. Process. Technol., vol. 8, no. 3, pp. 3440–3453, 2022, https://doi.org/10.1080/2374068X.2021.1970988.Search in Google Scholar
[26] C. Rajendran, M. V. Kumar, T. Sonar, and K. Mallieswaran, “Investigating the effect of PWHT on microstructural features and fatigue crack growth behavior of friction stir welded AA2024-T6 aluminum alloy joints,” Forces Mech., vol. 8, p. 100107, 2022, https://doi.org/10.1016/j.finmec.2022.100107.Search in Google Scholar
[27] U. M. Chaudry, S. C. Han, and T. S. Jun, “Effect of welding speed on the microstructure and texture development in the individual weld zone of friction stir welded DP780 steel,” J. Mater. Res. Technol., vol. 23, pp. 4976–4989, 2023, https://doi.org/10.1016/j.jmrt.2023.02.122.Search in Google Scholar
[28] R. H. Duan, Y. Q. Wang, Z. A. Luo, G. D. Wang, and G. M. Xie, “Hydrogen embrittlement behavior in the nugget zone of friction stir welded X100 pipeline steel,” Int. J. Hydrogen Energy, vol. 48, no. 22, pp. 8296–8309, 2023, https://doi.org/10.1016/j.ijhydene.2022.11.262.Search in Google Scholar
[29] Z. Zhang, Z. J. Tan, Y. F. Wang, D. X. Ren, and J. Y. Li, “The relationship between microstructures and mechanical properties in friction stir lap welding of titanium alloy,” Mater. Chem. Phys., vol. 296, p. 127251, 2023, https://doi.org/10.1016/j.matchemphys.2022.127251.Search in Google Scholar
[30] J. Song, H. Liu, J. Cui, et al.., “Crack initiation and short crack propagation of friction stir welded TC17 alloy joint,” Int. J. Fatigue, vol. 168, p. 107426, 2023, https://doi.org/10.1016/j.ijfatigue.2022.107426.Search in Google Scholar
[31] S. Manickam, C. Rajendran, S. R. Nathan, V. Sivamaran, and V. Balasubramanian, “Assessment of the influence of FSSW parameters on shear strength of dissimilar materials joint (AA6061/AZ31B),” Int. J. Lightweight Mater. Manuf., vol. 6, no. 1, pp. 33–45, 2023, https://doi.org/10.1016/j.ijlmm.2022.07.005.Search in Google Scholar
[32] C. Rajendran, K. Srinivasan, V. Balasubramanian, H. Balaji, and P. Selvaraj, “Feasibility study of FSW, LBW and TIG joining process to fabricate light combat aircraft structure,” Int. J. Lightweight Mater. Manuf., vol. 4, no. 4, pp. 480–490, 2021, https://doi.org/10.1016/j.ijlmm.2021.07.001.Search in Google Scholar
[33] S. R. Nathan, V. Balasubramanian, S. Malarvizhi, and A. G. Rao, “Effect of tool shoulder diameter on stir zone characteristics of friction stir welded HSLA steel joints,” Trans. Indian Inst. Met., vol. 69, pp. 1861–1869, 2016, https://doi.org/10.1007/s12666-016-0846-3.Search in Google Scholar
[34] S. R. Nathan, V. Balasubramanian, S. Malarvizhi, and A. G. Rao, “Effect of D/TP ratio on stir zone characteristics of friction stir-welded high-strength low-alloy steel plates,” Proc. Inst. Mech. Eng., Part L, vol. 232, no. 10, pp. 829–840, 2018, https://doi.org/10.1177/1464420716650.Search in Google Scholar
[35] S. R. Nathan, S. Malarvizhi, V. Balasubramanian, and A. G. Rao, “Failure analysis of tungsten based tool materials used in friction stir welding of high strength low alloy steels,” Eng. Failure Anal., vol. 66, pp. 88–98, 2016, https://doi.org/10.1016/j.engfailanal.2016.04.018.Search in Google Scholar
[36] S. R. Nathan, V. Balasubramanian, A. G. Rao, T. Sonar, M. Ivanov, and K. Suganeswaran, “Effect of tool rotational speed on microstructure and mechanical properties of friction stir welded DMR249A high strength low alloy steel butt joints for fabrication of light weight ship building structures,” Int. J. Lightweight Mater. Manuf., vol. 6, no. 4, pp. 469–482, 2023, https://doi.org/10.1016/j.ijlmm.2023.05.004.Search in Google Scholar
© 2023 Walter de Gruyter GmbH, Berlin/Boston
Articles in the same Issue
- Frontmatter
- Microstructure and properties of argon arc cladded CoCr x FeMoNiAl high entropy alloy coatings on Q235 steel
- Effects of different profiled pins used in friction stir welding of Al 6061 T6
- Effect of Ti3O5 addition on oxide evolution for HRB400
- Bulge test technique and digital image correlation for the determination of the biaxial behavior of polymeric films
- Effect of Cu addition on microstructure and corrosion behavior of Al–15Mg2Si composite
- Fracture failure analysis of an offshore drilling centralizer
- Influence of tool plunging rate on mechanical properties and microstructure of friction stir welded DMR249A high strength low alloy (HSLA) steel butt joints
- Modelling boron diffusion for Fe2B layer formation: comparative kinetics analysis in pack-boronized AISI 4147 steel
- Round bar notch shape optimization for tensile stress concentration testing
- Analysis of tool wear and surface roughness in machining of AISI 4462 duplex stainless steel
- Effects of build orientation and hatch spacing on high-speed milling behavior of L-PBF 316L stainless steel
- Physical and chemical properties of beads glasses
- Effect of polyurethane matrix and steel fiber in combination with glass fiber or basalt fiber on the properties of hybrid composite laminates
- Calibration of photoelastic materials with the disc under diametral compression
Articles in the same Issue
- Frontmatter
- Microstructure and properties of argon arc cladded CoCr x FeMoNiAl high entropy alloy coatings on Q235 steel
- Effects of different profiled pins used in friction stir welding of Al 6061 T6
- Effect of Ti3O5 addition on oxide evolution for HRB400
- Bulge test technique and digital image correlation for the determination of the biaxial behavior of polymeric films
- Effect of Cu addition on microstructure and corrosion behavior of Al–15Mg2Si composite
- Fracture failure analysis of an offshore drilling centralizer
- Influence of tool plunging rate on mechanical properties and microstructure of friction stir welded DMR249A high strength low alloy (HSLA) steel butt joints
- Modelling boron diffusion for Fe2B layer formation: comparative kinetics analysis in pack-boronized AISI 4147 steel
- Round bar notch shape optimization for tensile stress concentration testing
- Analysis of tool wear and surface roughness in machining of AISI 4462 duplex stainless steel
- Effects of build orientation and hatch spacing on high-speed milling behavior of L-PBF 316L stainless steel
- Physical and chemical properties of beads glasses
- Effect of polyurethane matrix and steel fiber in combination with glass fiber or basalt fiber on the properties of hybrid composite laminates
- Calibration of photoelastic materials with the disc under diametral compression
