Analysis of Material Flow and Phase Transformation in Friction Hydro-Pillar Processing of 1045 Steel

Subject Areas : welding

Moosa  Sajed ¹ (Department of Mechanical Engineering, University of Birjand, Iran)
S. M. Hossein  Seyedkashi ² (Department of Mechanical Engineering, University of Birjand, Iran)

Received: 2020-05-18 Accepted : 2020-07-22 Published : 2020-12-01

Keywords: 1045 Steel, Phase transformation, Material Flow, Solid-State Processing, Friction Hydro-Pillar Processing,

Abstract :

In the present study, a 3D finite element model was developed using DEFORM commercial software to analyse the material flow and phase transformation, as two key phenomena affecting the joint properties in friction hydro-pillar processing of 1045 steel alloy. The microstructure changes significantly due to the high temperature and strain rate. The final microstructure was intergranular pearlite and grain boundary allotriomorphic ferrite. Pearlite was the dominant phase at the final microstructure; thus, its volume fraction was used to validate the model where a good agreement was obtained with the experiment. According to the model, the pearlite volume fraction varies from 100% to 70% moving from the bottom of the stud to the top. The model suggests an inverse relation between the strain rate and pearlite volume fraction. The highest temperature which was experienced in the welding step was 1490 ºC while it dropped to 890 ºC in the forging step. Downward and then radial material flow was detected in the welding step while upward extrusion of material was the dominant material flow pattern during the forging step. Flash was formed mainly in the forging step from stud side material.

References:

[1]     Sattari, S., Bisadi, H., and Sajed., M., Mechanical Properties and Temperature Distributions of Thin Friction Stir Welded Sheets of AA5083, International Journal of Mechanics and Applications, Vol. 2, No. 1, 2012, pp. 1-6, DOI. 10.5923/j.mechanics.20120201.01

[2]     Sajed, M., Bisadi, H., Experimental Failure Study of Friction Stir Spot Welded Similar and Dissimilar Aluminum Alloys, Welding in the World, Vol. 60, No. 1, 2016, pp. 33-40, DOI. 10.1007/s40194-015-0268-6.

[3]     Cui, L., Yang, X., Wang, D., Cao, J., and Xu, W., Experimental Study of Friction Taper Plug Welding for Low Alloy Structure Steel: Welding Process, Defects, Microstructures, and Mechanical Properties, Materials & Design, Vol. 62, 2014, pp. 271-281, DOI. 10.1016/j.matdes.2014.05.026.

[4]     Buzzatti, D. T., Chludzinki, M., Santos, R. E., Buzzatti, J. T., Lemos, G. V. B., Mattei, F., Marinho, R. R., Paes, M. T. P., and Reguly, A., Toughness Properties of a Friction Hydro Pillar Processed Offshore Mooring Chain Steel, Journal of Materials Research and Technology, Vol. 8, No. 3, 2019, pp. 2625-2637, DOI. 10.1016/j.jmrt.2019.04.002.

[5]     Vicharapu, B., Kanan, L. F., Clarke, T., and De, A., An Investigation On Friction Hydro-Pillar Processing, Science and Technology of Welding and Joining Vol. 22, No. 7, 2017, pp. 555-561, DOI. 10.1080/13621718.2016.1274849.

[6]     Meinhardt, C. P., Chludzinski, M., Ribeiro, R. F., Rocha, C. L. F., Santos, A. C. S., and Strohaecker, T. R., Evaluation of Friction Hydro-Pillar Processing Welding in Duplex Stainless Steels (UNS S31803), Journal of Materials Processing Technology, Vol. 246, 2017, pp. 158-166, DOI. 10.1016/j.jmatprotec.2017.03.010.

[7]     Hattingh, D. G., Bulbring, D. L. H., Els-Botes, A., and James, M. N., Process Parameter Influence On Performance of Friction Taper Stud Welds in AISI 4140 steel, Materials & Design, Vol. 32, No. 6, 2011, pp. 3421-3430, DOI. 10.1016/j.matdes.2011.02.001.

[8]     Kanan, L. F., Vicharapu, B., Bueno, A. F. B., Clarke, T., and De, A., Friction Hydro-Pillar Processing of a High Carbon Steel: Joint Structure and Properties, Metallurgical and Materials Transactions B, Vol. 49, No. 2, 2018, pp. 699-708, DOI. 10.1007/s11663-018-1171-5.

[9]     Chludzinski, M., Paes, M. P., Bastian, F. L., and Strohaecker, T. R., Fracture Toughness of Friction Hydro-Pillar Processing Welding in C–Mn Steel, Materials & Design, Vol. 33, 2012, pp. 340-344, DOI. 10.1016/j.matdes.2011.07.056.

[10]  Yin, Y., Yang, X., Cui, L., Wang, F., and Li, S., Material Flow Influence On the Weld Formation and Mechanical Performance in Underwater Friction Taper Plug Welds for Pipeline Steel, Materials & Design, Vol. 88, 2015, pp. 990-998, DOI. 10.1016/j.matdes.2015.09.123.

[11]  Xu, Y. C., Jing, H. Y., Han, Y. D., and Xu, L. Y., Numerical Simulation of the Effects of Various Stud and Hole Configurations On Friction Hydro-Pillar Processing, International Journal of Mechanical Sciences, Vol. 90, 2015, pp. 44-52, DOI. 10.1016/j.ijmecsci.2014.10.025.

[12]  Li, W., Jiang, D., Yang, L., Pan, J., Qu, R., and Sun, T., Numerical Simulation of Temperature Field and Prediction of Microstructure in Friction Hydro Pillar Processing, Journal of Materials Processing Technology, Vol. 252, 2018, pp. 370-380, DOI. 10.1016/j.jmatprotec.2017.10.001.

[13]  Landell, R., Kanan, L. F., Buzzatti, D., Vicharapu, B., De A., and Clarke, T., Material Flow During Friction Hydro-Pillar Processing, Science and Technology of Welding and Joining, Vol. 25, No. 3, 2020, pp. 228-234, DOI. 10.1080/13621718.2019.1679963.

[14]  Sajed, M., Parametric Study of Two-Stage Refilled Friction Stir Spot Welding, Journal of Manufacturing Processes, Vol. 24, 2016, pp. 307-317, DOI. 10.1016/j.jmapro.2016.09.011.

[15]  Sajed, M., Seyedkashi, S. M. H., A Novel Technique for Keyhole-Less Reinforced Friction Stir Spot Welding of Polyethylene Sheets, International Journal of Advanced Design and Manufacturing Technology, Vol. 12, No. 4, 2019, pp. 47-56.

[16]  Sajed, M., Seyedkashi, S. M., Solid-State Micro-Alloying of Thick st37 Steel Plates with Sic Powder Using a Modified Friction Hydro-Pillar Process, Journal of Materials Research and Technology, Vol. 9, No. 4, 2020, pp. 7158-7171, DOI. 10.1016/j.jmrt.2020.04.068.

[17]  Jafarzadegan, M., Feng, A. H., Abdollah-Zadeh, A., Saeid, T., Shen, J., and Assadi, H., Microstructural Characterization in Dissimilar Friction Stir Welding Between 304 Stainless Steel and st37 Steel, Materials Characterization, Vol. 74, 2012, pp. 28-41, DOI. 10.1016/j.matchar.2012.09.004.

[18]  DEFORM, SFTC. "V11. 0 (PC) Documentation."