OPTIMIZATION OF PROCESS PARAMETERS FOR A SOLID-STATE-WELDED AISI 430 STEEL JOINT WITH THE GRG REINFORCED RESPONSE SURFACE METHODOLOGY
Keywords:
friction welding, optimization, response surface methodology, microstructure
Abstract
High-temperature applications such as heat exchangers and burner tubes employ AISI 430 steel. A larger heat-affected zone, undesired metallurgical changes and higher hardness in the weld area occur when fusion welding this type of steel. The study investigates the feasibility of welding ferritic stainless steel AISI 430, utilizing a solid-state method (continuous drive friction welding). The experiment uses an L27 orthogonal array and three levels of variation in the welding parameters such as frictional pressure, forging pressure, friction time, forging time and rotational speed. Tensile strength, axial shortening and impact toughness are the observed quality characteristics. In an integrated approach of the grey incidence reinforced response surface methodology, the benefits of the grey relational theory are merged with the statistical analysis of the response surface methodology to determine the ideal friction welding inputs (frictional pressure – 59.95 MPa, friction time – 4 s, upset pressure – 68.5 MPa, forging time – 3 s and rotational speed – 1399 min–1). The AISI 430 steel joint’s qualities are improved by 2.25, 12.74 and 7.89 % in terms of the maximum ultimate tensile strength, axial shortening and impact toughness, respectively.
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2. Potter, D.M.; Hansen, R.K.: Friction Welding Apparatus, System and Method. Patent No. US8123104B1 (2012)
3. Selvamani, S.T.; Vigneshwar, M.; Palanikumar, K.; Jayaperumal,D.: The corrosion behavior of fully deformed zone of friction welded low chromium plain carbon steel joints in optimized condition.J. Braz. Soc. Mech. Sci. Eng. 40, (2018), 305–317, doi:10.1007/s40430-018-1129-1.
4. Mohan Kumar, S.; Sankarapandian, S.; Siva Shanmugam, N.:Investigations on mechanical properties and microstructural examination of activated TIG-welded nuclear grade stainless steel. J Braz. Soc. Mech. Sci. Eng. 42, (2020),292, doi:10.1007/s40430-020-02393-4
5. Celik, S.; Ersozlu, I.: Investigation of the mechanical properties and microstructure of friction welded joints between AISI 4140 and AISI 1050 steel. Mater. Des. 30(2009) (4), 970–976, doi:10.1016/j.matdes.2008.06.070.
6. Ahmad Fauzi, M.N.; Uday, M.B.; Zuhailawati, H.; Ismail, A.B.:Microstructure and mechanical properties of alumina-6061aluminum alloy joined by friction welding. Mater. Des. 31(2010)
(2), 670–676, doi:10.1016/j.matdes.2009.08.019
7. Luo, J.; Wang, X.; Liu, D.; Li, F.; Xiang, J.: Inertia radial friction welding joint of large size H90 Brass/D60 steel dissimilar metals. Mater. Manuf. Process. 27(2012) (9), 930–935, doi:10.1080/10426914.2011.610087
8. Huang, Z.W.; Li, H.Y.; Baxter, G.; Bray, S.; Bowen, P.: Electron microscopy characterization of the weld line zones of inertia friction welded superalloy. J. Mater. Process. Technol. 211(2011) (12),1927–1936, doi:10.1016/j.jmatprotec.2011.06.019
9. Seli, H.; Ismail, A.I.M.; Rachman, E.; Ahmad, Z.A.: Mechanical evaluation and thermal modeling of friction welding of mild steel and aluminium. J. Mater. Process. Technol. 210(2010)
(9), 1209–1216, doi:10.1016/j.jmatprotec.2010.03.007
10. M. Kimura, K. Suzuki, M. Kusaka, and K. Kaizu.: “Effect of friction welding condition on joining phenomena, tensile strength, and bend ductility of friction welded joint between pure aluminium and AISI 304 stainless steel" Journal of Manufacturing Processes.25 (2017),116–125, doi:10.1016/j.jmapro.2016.12.001
11. M. Kimura, K. Suzuki, M. Kusaka, and K. Kaizu.: “Effect of friction welding condition on joining phenomena and mechanical properties of friction welded joint between 6063 aluminium alloy and AISI 304 stainless steel" Journal of Manufacturing Processes 26(2017),178–187, doi:10.1016/j.jmapro.2017.02.008
12. G. Senthilkumar and R. Ramakrishnan.: “Design of Optimal Parameter for Solid-State Welding of EN 10028-P355 GH Steel Using gray Incidence Reinforced Response Surface Methodology" Arabian Journal for Science and Engineering 46 (2021) (3), 2613–2628, doi:10.1007/s13369-020-05169-z
13. G. Senthilkumar, T. Mayavan, R. Ramakrishnan.: “Optimization for Friction Welding Input Factors to Maximize Tensile Strength and Minimize Axial Shortening in ASTM A516 Grade 70 steel Rods" Journal of Applied Science and Engineering 25(2021) (5), 773–784, doi:10.6180/jase.202210_25(5).0008
14. Correia, D.S.; Goncalves, C.V.; Cunha, S.S.; Ferraresi, V.A.:Comparison between genetic algorithms and response surface methodology in GMAW welding optimization. J. Mater. Process.Technol. 160(2005) (1), 70–76, doi:10.1016/j.jmatprotec.2004.04.243
15. Ajith, P.M.; Afsal Husain, T.M.; Sathiya, P.; Aravindan, Multi-objective optimization of continuous drive friction welding process parameters using response surface methodology with the intelligent optimization algorithm. J. Iron Steel Res. Int.22, (2015), 954–960, doi:10.1016/S1006-706X(15)30096-0
16. Santhanakumar, M.; Adalarasan, R.; Siddharth, S.; Velayudham,A.: An investigation on surface finish and flank wear in hard machining of solution treated and aged 18% Ni maraging steel.J. Braz. Soc. Mech. Sci. Eng. 39, (2017), 2071–2084, doi:10.1007/s40430-016-0572-0
17. Kadaganchi, R.; Gankidi, M.R.; Gokhale, H.: Optimization of process parameters of aluminum alloy AA 2014–T6 friction stir welds by response surface methodology. Def. Technol. 11(2015) (3), 209–219, doi:10.1016/j.dt.2015.03.003
18. Atcharawadi, T.; Boonruang, C.: Design of boiler welding for improvement of lifetime and cost control. Materials. 9 (2016) (11), 891–906, doi:10.3390/ma9110891
19. R. Selvaraj, K. Shanmugam, P. Selvaraj, Bellamkonda Prasanna Nagasai, Visvalingam Balasubramanian.: Optimization of Process Parameters of Rotary Friction Welding of Low Alloy Steel Tubes Using Response Surface Methodology. Forces in Mechanics, (2023), 100175, doi:10.1016/j.finmec.2023.100175
20. Banerjee, Amborish, Michail Ntovas, Laurie Da Silva, and Salaheddin Rahimi.: "Microstructure and mechanical properties of dissimilar inertia friction welded 316L stainless steel to A516 ferritic steel for potential applications in nuclear reactors." Manufacturing Letters 33, (2022), 33-37, doi:10.1016/j.mfglet.2022.07.002
21. Zhang, Kejin, Xusheng Qian, Jieshi Chen, Junmei Chen, and Hao Lu. "Non-monotonic evolution of microstructure and fatigue properties of the round bar–plate rotary friction welding joints in 304 austenitic stainless steel. Materials & Design 224, (2022),111400, doi:10.1016/j.matdes.2022.111400
22. Winiczenko, Radosław, and Mieczysław Kaczorowski. "Friction welding of ductile cast iron using interlayers." Materials & Design 34, (2012), 444-451, doi:10.1016/j.matdes.2011.08.038
23. Sathiya, P., S. Aravindan, and A. Noorul Haq. "Effect of friction welding parameters on mechanical and metallurgical properties of ferritic stainless steel." The International Journal of Advanced Manufacturing Technology.31, (2007),1076-1082, doi:10.1007/s00170-005-0285-5
Published
2023-10-03
How to Cite
1.
G.S, Vinodkumar V, Mayavan T, Rathinasabapathi G, G DavidA. OPTIMIZATION OF PROCESS PARAMETERS FOR A SOLID-STATE-WELDED AISI 430 STEEL JOINT WITH THE GRG REINFORCED RESPONSE SURFACE METHODOLOGY. MatTech [Internet]. 2023Oct.3 [cited 2026Aug.14];57(5):485–494. Available from: https://www.mater-tehnol.si/index.php/MatTech/article/view/873
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