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An investigation into joining of austenitic-stainless steels (AISI 304) with friction welding
Mumin Sahin
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Mumin Sahin, (2005),"An investigation into joining of austenitic-stainless steels (AISI 304) with friction welding", Assembly
Automation, Vol. 25 Iss 2 pp. 140 - 145
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Mümin Sahin, H. Erol Akata, (2004),"An experimental study on friction welding of medium carbon and austenitic stainless steel
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H. Erol Akata, Mumin Sahin, (2003),"An investigation on the effect of dimensional differences in friction welding of AISI 1040
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 Research article

An investigation into joining of austenitic-

stainless steels (AISI 304) with friction welding
Mumin Sahin
Department of Mechanical Engineering, Trakya University, Edirne, Turkey

Abstract
Purpose – Aims to determine if friction welding is suitable for welding austenitic stainless steel (AISI 304)
Design/methodology/approach – Uses an experimental continuous drive friction welding set-up. Determined the strength, hardness and
microstructure of the joined parts.
Findings – Finds that the joint strengths are 96 per cent of those of the base metals with no significant hardening.
Practical implications – Friction welding is an appropriate joining method for austenitic stainless steel (AISI 304).
Originality/value – Aids in understanding appropriate uses of friction welding for joining stainless steel.
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Keywords Friction welding, Stainless steel, Bonding

Paper type Research paper

1. Introduction the axial pressure is being increased to a higher predetermined

maximum upset pressure (Pu) for a predetermined time (tu).
Friction welding has been used for many years to solve the Parameters of the welding method are shown in Figure 1
problem of joining materials and steels. Little or no melting
(Sahin and Akata, 2003).
occurs along the weld interface. In the process, heat is Different studies about friction welding have been
generated by conversion of mechanical energy into thermal
investigated by various researchers:
energy at the interfaces of the components during rotation
Vill (1962) and Tylecote (1968) investigated the friction
under pressure without any external energy from the
welding method. Jenning (1971) investigated the properties of
environment. Some of the advantages of friction welding are
the dissimilar materials welded by friction welding. Lucas
high material saving, low production time and the possibility
(1971) investigated process parameters of the friction welding
of the welding of parts.
The most important parameters in friction welding are method. Kinley (1979) investigated the inertia friction
friction time, friction pressure, upset time, upset pressure and welding method. Fomichev (1980) made a study about the
rotation speed. The parameters affecting the welding quality friction welding of high-speed tool steels to structural steels.
are the joint strength and hardness of the heat affected zone Later, Ellis (1977) examined the relationship between
(HAZ) and welding zone. Therefore, the parameters are “friction time-workpiece diameter”, “shortening-upsetting
selected properly in the experiments. In general, friction pressure” and “carbon equivalent-hardness variation”.
welding is accomplished either by continuous drive friction Ishibashi et al. (1983) analyzed distributions of alloying
welding or inertial friction welding. elements at and near the weld interfaces for joints of sufficient
In the continuous drive method, one of the components is strength using an X-ray micro-analyzer. Murti and
rotated at constant speed (s), while the other is pushed Sundaresan (1983) made a study about parameter
towards the rotated part by a sliding action under a optimization in friction welding of dissimilar materials.
predetermined friction pressure (Pf). Friction pressure (Pf) Dunkerton (1986) investigated the effects of rotation speed,
is applied for a certain friction time (tf). Then the drive is friction pressure and upsetting pressure in all friction welding
released and the rotary component is quickly stopped while methods for steel. Nentwig (1996) investigated the effect on
cross-sectional differences of the components on the joint
The Emerald Research Register for this journal is available at quality of friction welds. Mortensen et al. (2001) joined 416
www.emeraldinsight.com/researchregister stainless steel, resulphurized steel, by inertia friction welding
The current issue and full text archive of this journal is available at method. They investigated mechanical properties and
www.emeraldinsight.com/0144-5154.htm microstructures of 416 stainless steel.

The author thanks to Trakya University/Edirne – Turkey and Hema

Assembly Automation
25/2 (2005) 140– 145
Industry/Çerkezköy – Turkey for the helps in experimental part of the
q Emerald Group Publishing Limited [ISSN 0144-5154] study. The author also thanks to Prof. Dr H. Erol AKATA, Trakya
[DOI 10.1108/01445150510590505] University/Edirne – Turkey, for advices.

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Mumin Sahin Volume 25 · Number 2 · 2005 · 140 –145

Figure 1 Parameters on continuous drive friction welding 2.2 Work-piece material

AISI 304 austenitic-stainless steel couples were used in the
friction welding experiments. The chemical compositions and
measured tensile strengths of the test materials are given in
Table I. The standard chemical compositions were taken from
Stahlschlüssel (Wegst, 1995). Friction welding experiment of
parts is schematically shown in Figure 3.

3. Selection of welding parameters using

statistical approach
When a statistician suggests the experimental runs to be made
in a series of tests, data analysis can be quite straightforward.
However, often an analysis must be carried out on results that
have been accumulated as part of a test program or as a series
of related test programs and an empirical predictive model
must be constructed from the results obtained. Terms for
Then, Sahin and Akata (2001) investigated welding quality
possible inclusion in the model might involve not only the
using tensile test results of welded parts having different cross-
principal variables but also variables such as cross products,
sections. Sahin and Akata (2002a, b) directed a study about
squares, or other combinations, or transformations, of the
friction welding of medium-carbon steel and austenitic-
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principal variables (Draper and Smith, 1981).

stainless steel. Sahin and Akata (2002a, b) made a study on The basis of this approach is the assumption of a simplified
joining with friction welding of stainless steels. Later, Akata linear model for the optimisation parameter h given by h ¼
and Şahin (2003) made investigation on the effect of b0 þ b1 x1 þ b2 x2 þ · · ·; where x1 ; x2 ; . . . are the factors on
dimensional differences in friction welding of aisi 1040 which h depends and b0 ; b1 ; b2 ; . . . represent the “true” values
specimens. Sahin and Akata (2003) investigated joining of of the corresponding unknowns. From the results of an
friction welding with plastically deformed carburizing steel. experiment comprising a finite number of trials, one can
An experimental study on friction welding of medium-carbon arrive at sample estimates of the coefficients, b, which are
and austenitic-stainless steel components was made by Sahin then usually fitted into a linear regression equation of the type
and Akata (2004). y ¼ b0 þ b1 x1 þ b2 x2 þ · · · where y is the response function
In the presented study, the appropriateness for friction and the bs are the “estimated” values of the bs. In simple
welding of the steel and the welding strength of the joints were terms, each coefficient represents the influence of the
investigated using austenitic-stainless steel (AISI 304). corresponding factor on the quality of the weld expressed by
the optimisation parameter.
The statistical analysis involves two steps: first, the
2. Experimental procedure adequacy of the model is tested. A suitable method is based
on the Fischer or “F” ratio, which can be used to confirm if
the terms in the assumed linear function are statistically
2.1 Experimental set-up significant. The second step is to obtain optimal estimates of
The friction welding set-up designed and constructed the regression coefficients for the significant factors, which
beforehand for experiments is shown in Figure 2 (Sahin and may be done using the method of least squares (Murti and
Akata, 2003). Sundaresan, 1983).
Parameter optimisation was carried out using factorial
Figure 2 The friction welding set-up design of experiments. The two factors chosen were friction
time and friction pressure. The other parameters such as
upset time, upset pressure and rotational speed were
maintained constant. Experimental results for factors are
given in Table II.

4. The statistical approach results

First, optimal estimates of regression coefficients were
obtained using the Fisher ratio method. The prediction
equation is also given below.
y ¼ 2581:696 þ 15:465x1 þ 46:226x2

Later, parameters having the least error using the method of

least squares were taken as the optimum welding parameters.
The optimum welding conditions are given in Table III.
As a result, the optimum parameters found were:
friction time ¼ 9 s, friction pressure ¼ 60 MPa, upset time ¼
20 s and upset pressure ¼ 110 MPa:

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Mumin Sahin Volume 25 · Number 2 · 2005 · 140 –145

Table I The chemical composition of the material used in the experiments

Material C (per cent) P (per cent) S (per cent) Mn (per cent) Si (per cent) Cr (per cent) Ni (per cent) Tensile strength (MPa)
AISI 304 (X5CrNi1810) ,0.07 ,0.045 ,0.030 ,2.0 ,1.0 17-19 8.5-10.5 825

Figure 3 Parts used in the experiments

Table II Experimental results for factors

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Trial no. Friction pressure (MPa) x1 Friction time (s) x2 Tensile strength (MPa)
1 20 9 80
2 45 9 700
3 60 9 795.8
4 60 3 450
5 60 11 750

Table III Optimum welding conditions

Metal Friction pressure (MPa) Friction time (s) Upset pressure (MPa) Upset time (s) Rotational speed (rpm)
Austenitic stainless-steel 60 9 110 20 1,440

Later, the tensile strengths of the joints obtained were between the tensile strength versus the friction time and the
investigated and the results were compared with those of fully friction pressure are shown graphically in Figures 4 and 5.
machined ones. Tensile tests were applied after machining As the friction time and pressure for the joints increases, as
the weld flashes. Tensile strengths were calculated dividing the shown in Figures 4 and 5, the tensile strength of the joints
ultimate loads by area of 10 mm diameter. increases. But, the strength of the joints raises to a maximum,
and later, when the friction time and pressure for the joints
are increased, the tensile strength of the joints decreases. The
5. The experimental results and discussion maximum tensile strength of the joints is also harmonious
5.1 The tensile tests with obtained optimum parameters using a statistical
The strengths of welded joints were determined using a approach.
universal hydraulic tensile machine. Tensile tests were applied Then the joints were deformed when the friction time and
after machining of the weld flashes formed during the welding pressure for the joints were increased, and the required
process. The tensile strengths of the joints were calculated by bonding for friction welding did not take place in the joints.
dividing the ultimate loads with cross section of trimmed Then, the maximum obtained strength in the joints was about
welding zone. 96 per cent of that of base austenitic-stainless steel parts.
The effects of friction time and friction pressure on the
strength of the joints were investigated in welding of equal
diameter parts. Two sets of welding experiments keeping the 5.2 Microstructure of welded parts
upset time and upset pressure (Welding and Brazing, 1981) Macro-photo of joint after etched in picral is shown in
constant were directed to obtain proper friction time and Figure 6 and photos of microstructures in the HAZ were also
friction pressure. In the first set, friction times were changed taken. Microstructure-photos in the parent metals, heat-
while friction pressure (60 MPa) was kept constant. In the affected zone and interface region of the joints after etched in
second set, friction pressures were changed while friction picral are shown in Figures 7-9.
time (9 s) was kept constant. The strengths of the joints were Figure 6 shows the central axial-section of welded joints. As
determined by tensile tests, and the results were compared it can be easily seen from Figure 6, the burr that is produced
with those of fully machined ones. Obtained relationship in the equal steel joints is identical to both stainless steel sides.

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Figure 4 Relationship between tensile strength versus friction time Figure 6 Macro-photograph of joint, as welded
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Figure 7 Microstructure of AISI 304 steel

Figure 5 Relationship between tensile strength versus friction pressure

Figure 8 Microstructure of HAZ on the welded joints, as welded

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Figure 9 Microphotograph of weld interface, as welded

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The microstructures taken from the base material and HAZ 6. Conclusions
consist of an austenitic-grain structure. It can be seen that the .
In this study, austenitic-stainless steels (AISI 304)
microstructure of the welding metal of the joint has a
were welded successfully using an experimental set-up,
homogeneous-austenitic structure.
continuous drive friction welding method with satisfactory
results for tensile strength considerations.
.
Optimum welding parameters should be properly
5.3 Hardness variations of welded parts
selected in friction welding of various materials and
Increase and decrease in strength is related to hardness
steels.
variation within the HAZ. Hardness variation was obtained by .
Statistical analysis is an economical and reliable method
Vickers hardness testing and measuring locations are shown in
for optimising welding parameters.
Figure 10. Macro-photo of the joint after etching in picral is . In order to obtain welded joints with sufficient
also shown in Figure 10. Hardness variations on the tensile strength, adequate welding conditions were
horizontal direction and on the vertical direction of welded investigated for the friction welding of austenitic-
parts are shown in Figures 11 and 12. stainless steels. The tensile strengths of the welded joints
Figure 11 shows the hardness distribution in the welded are nearly equal to those of the base metals, AISI 304
joint made by austenitic-stainless steels. As it is seen in stainless steel.
Figure 11, the hardness of the joints decreases on interface .
AISI 304 austenitic-stainless steel has no considerable
zone of the joint. On the other hand, as it is seen in Figure 12, hardening effect in the welding zone of joints as can be
there is a slight decrease towards the side of parts in the seen from the hardness variations and microstructures.
vertical distance of the joints. These are due to the fact that .
Friction welding can easily be used for the welding of
the AISI 304 steel is not hardenable by heat treatment. different steels and materials.

Figure 10 Hardness test orientations

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Mumin Sahin Volume 25 · Number 2 · 2005 · 140 –145

Figure 11 Hardness variations on horizontal distance around the weld Draper, N.R. and Smith, H. (1981), Applied Regression
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Ellis, C.R.G. (1977), “Friction welding, some recent
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