Tensile efficiency and fatigue life of similar and dissimilar carbon steel joints subjected to rotary friction welding
Rotary friction welding (RFW) is a solid-state welding method that can address the melting point limitation of other welding types; however, the welded area remains at risk of failure due to fatigue during operation. Fatigue failure is difficult to detect and predict, making it a critical failure mo...
| Main Authors: | , , , |
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| Format: | Article |
| Language: | English |
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Elsevier
2023-11-01
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| Series: | Journal of Advanced Joining Processes |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2666330923000304 |
| _version_ | 1797394751859720192 |
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| author | Madyan Abduljabbar Marir Ewe Lay Sheng Imad Obaid Bachi Mohd Rashdan Isa |
| author_facet | Madyan Abduljabbar Marir Ewe Lay Sheng Imad Obaid Bachi Mohd Rashdan Isa |
| author_sort | Madyan Abduljabbar Marir |
| collection | DOAJ |
| description | Rotary friction welding (RFW) is a solid-state welding method that can address the melting point limitation of other welding types; however, the welded area remains at risk of failure due to fatigue during operation. Fatigue failure is difficult to detect and predict, making it a critical failure mode in engineering. Although many fatigue life prediction methods are available, they do not consider the impact of RFW parameters (such as pressure, speed, and friction time) on fatigue strength. Owing to their good mechanical properties and commercial viability, carbon steel of grades C35 and C45 is commonly applied to manufacture main parts in the automotive industry. This study centers on employing RFW to join C35 and C45, representing the first-ever instance of using this technique to weld them together. The primary goal of RFW for C35 and C45 is to construct optimum parts that meet specific design requirements and have a long fatigue life. Findings showed C45–C45 joints (77 %) were more tensile-efficient than C35–C35 joints (73 %). Dissimilar C35–C45 joints reached 60 % of C45 base metal and 76 % of C35 base metal in terms of tensile efficiency. RFW welds had lower tensile strength than their base metals. Optimal results came at 35 MPa friction pressure and 8–12 s friction time for both similar and dissimilar RFW joints using the Coffin–Manson method, dissimilar C33–C45 joint fatigue life improved by over 85 %, aligning C35 and C45 engineering aspects. SEM microstructure analysis showed two regions: non-deformed (NDZ) and plastically deformed (PDZ), with broader PDZ indicating better tensile strength. These findings enhance RFW's efficiency, promoting automotive part longevity and safety. |
| first_indexed | 2024-03-09T00:24:08Z |
| format | Article |
| id | doaj.art-3f3b428d20064ecca2bb794eece387f2 |
| institution | Directory Open Access Journal |
| issn | 2666-3309 |
| language | English |
| last_indexed | 2024-03-09T00:24:08Z |
| publishDate | 2023-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Advanced Joining Processes |
| spelling | doaj.art-3f3b428d20064ecca2bb794eece387f22023-12-12T04:36:29ZengElsevierJournal of Advanced Joining Processes2666-33092023-11-018100168Tensile efficiency and fatigue life of similar and dissimilar carbon steel joints subjected to rotary friction weldingMadyan Abduljabbar Marir0Ewe Lay Sheng1Imad Obaid Bachi2Mohd Rashdan Isa3Department of Mechanical Engineering, College of Engineering, University Tenaga Nasional, Kajang, Malaysia; General Company for ports of Iraq, Ministry of Transportation, Iraq; Corresponding author.Department of Mechanical Engineering, College of Engineering, University Tenaga Nasional, Kajang, MalaysiaMaterials Engineering Department, College of Engineering, University of Basrah, IraqDepartment of Mechanical Engineering, College of Engineering, University Tenaga Nasional, Kajang, MalaysiaRotary friction welding (RFW) is a solid-state welding method that can address the melting point limitation of other welding types; however, the welded area remains at risk of failure due to fatigue during operation. Fatigue failure is difficult to detect and predict, making it a critical failure mode in engineering. Although many fatigue life prediction methods are available, they do not consider the impact of RFW parameters (such as pressure, speed, and friction time) on fatigue strength. Owing to their good mechanical properties and commercial viability, carbon steel of grades C35 and C45 is commonly applied to manufacture main parts in the automotive industry. This study centers on employing RFW to join C35 and C45, representing the first-ever instance of using this technique to weld them together. The primary goal of RFW for C35 and C45 is to construct optimum parts that meet specific design requirements and have a long fatigue life. Findings showed C45–C45 joints (77 %) were more tensile-efficient than C35–C35 joints (73 %). Dissimilar C35–C45 joints reached 60 % of C45 base metal and 76 % of C35 base metal in terms of tensile efficiency. RFW welds had lower tensile strength than their base metals. Optimal results came at 35 MPa friction pressure and 8–12 s friction time for both similar and dissimilar RFW joints using the Coffin–Manson method, dissimilar C33–C45 joint fatigue life improved by over 85 %, aligning C35 and C45 engineering aspects. SEM microstructure analysis showed two regions: non-deformed (NDZ) and plastically deformed (PDZ), with broader PDZ indicating better tensile strength. These findings enhance RFW's efficiency, promoting automotive part longevity and safety.http://www.sciencedirect.com/science/article/pii/S2666330923000304Rotary friction weldingC35C45Tensile efficiencyFatigue life |
| spellingShingle | Madyan Abduljabbar Marir Ewe Lay Sheng Imad Obaid Bachi Mohd Rashdan Isa Tensile efficiency and fatigue life of similar and dissimilar carbon steel joints subjected to rotary friction welding Journal of Advanced Joining Processes Rotary friction welding C35 C45 Tensile efficiency Fatigue life |
| title | Tensile efficiency and fatigue life of similar and dissimilar carbon steel joints subjected to rotary friction welding |
| title_full | Tensile efficiency and fatigue life of similar and dissimilar carbon steel joints subjected to rotary friction welding |
| title_fullStr | Tensile efficiency and fatigue life of similar and dissimilar carbon steel joints subjected to rotary friction welding |
| title_full_unstemmed | Tensile efficiency and fatigue life of similar and dissimilar carbon steel joints subjected to rotary friction welding |
| title_short | Tensile efficiency and fatigue life of similar and dissimilar carbon steel joints subjected to rotary friction welding |
| title_sort | tensile efficiency and fatigue life of similar and dissimilar carbon steel joints subjected to rotary friction welding |
| topic | Rotary friction welding C35 C45 Tensile efficiency Fatigue life |
| url | http://www.sciencedirect.com/science/article/pii/S2666330923000304 |
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