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Effect of Tool Offset and Rotational Speed in Dissimilar Friction Stir Welding of AISI 304 Stainless Steel and Mild Steel

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Abstract

In the present study, dissimilar friction stir welding was carried out between stainless steel (UNS S30400) and mild steel (UNS G10080) plates of 4 mm thickness using a tungsten carbide tool. The influence of tool rotational speeds (600, 875 rpm) and tool offsets (0.6, 1.2 mm) on mechanical properties, i.e., hardness, tensile strength, and impact toughness of welded joints was investigated. Maximum tensile strength of the joint was about 107.6% of the mild steel under rotational speed of 875 rpm and tool offset of 1.2 mm. The maximum hardness reached in the stir zone was about 281 HV0.5 due to the phase transformations and grain refinement. Charpy’s notch toughness of the welded joints was observed lower than the base materials. The microstructural characterizations were carried by using an optical microscope, and FESEM–EDS analysis which revealed the complex material mixing and material movement during the welding. Tungsten-rich bands were observed in the weld micrograph especially toward the advancing side. During this study, various wear mechanisms like oxidation wear, abrasive wear, and adhesion wear were responsible for the degradation of tungsten carbide tool.

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Acknowledgments

The authors gratefully acknowledge the financial support provided by Naval Research Board (NRB), Govt. of India. The authors are also thankful to the Department of Mechanical Engineering, Central Instruments Facility and Department of Physics of IIT Guwahati, for providing the required research facilities.

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  1. Department of Mechanical Engineering, Indian Institute of Technology Guwahati, Guwahati, Assam, 781039, India

    Avinish Tiwari, Piyush Singh, Pardeep Pankaj, Pankaj Biswas, Sachin D. Kore & Sukhomay Pal

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  1. Avinish Tiwari
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Correspondence to Avinish Tiwari.

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Tiwari, A., Singh, P., Pankaj, P. et al. Effect of Tool Offset and Rotational Speed in Dissimilar Friction Stir Welding of AISI 304 Stainless Steel and Mild Steel. J. of Materi Eng and Perform 28, 6365–6379 (2019). https://doi.org/10.1007/s11665-019-04362-y

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