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Friction Stir Welding in HSLA-65 Steel: Part I. Influence of Weld Speed and Tool Material on Microstructural Development

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Abstract

A systematic set of single-pass full penetration friction stir bead-on-plate and butt-welds in HSLA-65 steel were produced using a range of different traverse speeds (50 to 500 mm/min) and two tool materials (W-Re and PCBN). Microstructural analysis of the welds was carried out using optical microscopy, and hardness variations were also mapped across the weld-plate cross sections. The maximum and minimum hardnesses were found to be dependent upon both welding traverse speed and tool material. A maximum hardness of 323 Hv(10) was observed in the mixed martensite/bainite/ferrite microstructure of the weld nugget for a welding traverse speed of 200 mm/min using a PCBN tool. A minimum hardness of 179 Hv(10) was found in the outer heat-affected zone (OHAZ) for welding traverse speed of 50 mm/min using a PCBN tool. The distance from the weld centerline to the OHAZ increased with decreasing weld speed due to the greater heat input into the weld. Likewise for similar energy inputs, the size of the transformed zone and the OHAZ increased on moving from a W-Re tool to a PCBN tool probably due to the poorer thermal conductivity of the PCBN tool. The associated residual stresses are reported in Part II of this series of articles.

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  1. TRI-FLUTE is a trademark of TWI Ltd., Granta Park, Great Abington, Cambridge, UK.

  2. TRI-FLUTE is a trademark of TWI Ltd., Granta Park, Great Abington, Cambridge, UK.

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Acknowledgments

The authors acknowledge the work of Lyn Drewett, Corus RDandT Centre. EPSRC is acknowledged for funding, including the FSW program of the Light Alloys Portfolio Partnership (Grant No. EP/DO29201/1).

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Author notes

  1. A. R. Bhatti (Research Assistant, Postdoctoral Research Assistant)

    Present address: Department of Materials Science and Metallurgy, University of Cambridge, Cambridge, CB2 3QZ , United Kingdom

  2. J. Altenkirch (Researcher, Project Manager)

    Present address: Siemens AG, Mülheim an der Ruhr, D-45473, Germany

Authors and Affiliations

  1. School of Materials, Materials Science Centre, University of Manchester, Manchester, M13 9PL, United Kingdom

    S. J. Barnes (NDT Manager), A. R. Bhatti (Research Assistant, Postdoctoral Research Assistant), J. Altenkirch (Researcher, Project Manager) & P. J. Withers (Professor of Materials Science)

  2. ESS Scandinavia, University of Lund, 22350, Lund, Sweden

    A. Steuwer (Visiting Professor for Materials Engineering)

  3. NMMU, Port Elizabeth, 6031, South Africa

    A. Steuwer (Visiting Professor for Materials Engineering)

  4. TWI Yorkshire, Wallis Way, Catcliffe, Rotherham, S60 5TZ, United Kingdom

    R. Johnson (Project Leader)

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  1. S. J. Barnes
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Correspondence to S. J. Barnes.

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Manuscript submitted July 14, 2010.

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Barnes, S.J., Bhatti, A.R., Steuwer, A. et al. Friction Stir Welding in HSLA-65 Steel: Part I. Influence of Weld Speed and Tool Material on Microstructural Development. Metall Mater Trans A 43, 2342–2355 (2012). https://doi.org/10.1007/s11661-012-1110-z

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