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Materials Science and Engineering A
Materials Science and Engineering A
a r t i c l e i n f o a b s t r a c t
Article history: The present study focuses on the effect of the welding speed on the microstructure and mechanical
Received 11 April 2008 properties of the stir zone (SZ) in friction stir welding (FSW) of SAF 2205 duplex stainless steel. A single
Received in revised form 8 May 2008 tool, made of a WC-base material, was used to weld 2 mm-thick plates at a constant rotational speed
Accepted 9 May 2008
of 600 rpm. X-ray radiography revealed that sound welds were successfully obtained for the welding
speeds in the range of 50–200 mm/min, whereas a groove-like defect was formed at the higher speed
Keywords:
of 250 mm/min. Moreover, increasing the welding speed decreased the size of the ˛ and grains in the
Friction stir welding
SZ, and hence, improved the mean hardness value and the tensile strength of the SZ. These results are
Duplex stainless steel
Microstructure interpreted with respect to interplay between the welding speed and the peak temperature in FSW.
Mechanical properties © 2008 Published by Elsevier B.V.
2. Experimental procedure
∗ Corresponding author. Tel.: +98 21 88005040; fax: +98 21 88005040. Bead-on-plate welding of a commercial SAF 2205 duplex stain-
E-mail address: zadeh@modares.ac.ir (A. Abdollah-zadeh). less steel was performed in the present study. The chemical
Table 1 and mechanically ground with water abrasive paper and polished in
Chemical composition (in wt%) and mechanical properties of the base metal
a standard metallography procedure. Then, provided samples were
Cr 22.31 electrolytically etched in a solution of 56 g KOH in 100 mL water at
Ni 5.48 3 V for 30 s.
Mo 3.34
In order to identify the present phases, X-ray diffraction (XRD)
Mn 1.42
C 0.03
analysis was carried out using a PHILIPS® diffractometer, model
P 0.023 X’Pert, with step size of 0.04 and time per step of 0.8 s. It was used
S 0.005 with Cu K␣ radiation at 40 kV and 40 mA.
Tensile strength (MPa) 834 ± 3.6 The Vickers hardness profile of the weld was measured on the
Hardness (HV ) 266 ± 2
cross-section perpendicular to the welding direction at the cen-
ter of the thickness with a 4.9 N load for 10 s. Longitudinal tensile
composition and mechanical properties of the base material is specimens were extracted from welded samples and prepared in
listed in Table 1. This material was cut in to specimens with dimen- accordance with ASTM E8. Tensile tests were carried out at room
sions of 300 mm × 100 mm × 2 mm. temperature at a crosshead speed of 0.05 mm/s.
The provided samples were friction stir welded along the rolling
3. Results and discussion
direction using a vertical milling machine. FSW tool, which was
made of a WC-based material, had a shoulder diameter of 16 mm,
3.1. Inspection of FSW joint
pin diameter of 5 mm and 1.5 mm pin length. The tool was tilted
3◦ from the plate normal direction. Since the machine and tool
The X-ray radiographies of the welds with various welding
were exposed to high temperatures during FSW, a liquid cooled tool
speeds are shown in Fig. 1. It is clearly seen that sound joints are
holder was used. In order to avoid the surface oxidation, Ar shield-
obtained up to the welding speed of 200 mm/min. However, at a
ing gas was introduced around the tool at a flow rate of 18 L/min.
higher speed of 250 mm/min, a groove-like defect is observed in
Five welds were made with the same rotational speed, 600 rpm,
the joint advancing side (Fig. 1e). This defect can seriously degrade
but different welding speeds of 50, 100, 150, 200, and 250 mm/min.
the mechanical properties of the weld metal [21]. Previous stud-
The length of each weld was 270 mm. In addition to the mentioned
ies [22,23] revealed that groove-like defects are primarily formed
welding parameters, the axial pressure or the insertion depth of pin
when the heat input during FSW is insufficient. In this situation,
into the workpiece is important for producing sound welds and has
the material could not easily flow to fill up the gap generated by
to be properly chosen initially [20–22]. The insertion depth of pin
the tool pin.
into workpiece was held constant at 1.7 mm during welding trials.
As will be described in subsequent section, one of the key param-
This depth was corresponding to initial Z-axis force of about 14 kN.
eters that have an essential influence on the heat input is the
Plate temperature was measured on the bottom surfaces of the
welding speed. With increasing the welding speed, the heat input
plates at the centerline using a K-type thermocouple. Thermocou-
would be decreased gradually up to a limit that the generated fric-
ple was set in the 1.5-mm diameter hole in a carbon steel backing
tional heat is insufficient to allow viscoplastic material flow and
plate and fastened by the copper paste so as not to come out during
therefore, the groove-like defect is more likely to occur.
FSW.
Following FSW, visual and X-ray radiography inspections of 3.2. The weld thermal history
the FSW joints were performed to reveal the weld defects on the
surfaces and in the inner zones of the welded joint. Microstruc- Fig. 2 presents a typical temperature profile and recorded peak
tural observations were performed by optical microscopy (OM) temperatures of the sound welds fabricated at different welding
and scanning electron microscopy (SEM) equipped with an speeds. It can be seen that the peak temperature decreases with
energy-dispersive X-ray spectroscopy (EDS) analysis system. Metal- increasing welding speeds at a constant tool rotational speed. Sim-
lographic samples were cut perpendicular to the welding direction ilar results have been reported for carbon steels [8] and 304L
Fig. 1. X-ray radiographs of FSW joints in various welding speeds: (a) = 50 mm/min, (b) = 100 mm/min, (c) = 150 mm/min, (d) = 200 mm/min, and (e) = 250 mm/min.
264 T. Saeid et al. / Materials Science and Engineering A 496 (2008) 262–268
Table 2
Calculated amounts of net heat input at various friction stir welding speeds
where Q is the net heat input same as Eq. (3) (J/mm), d the material
thickness (mm), and k is the thermal coefficient (J/mm2 s1/2 ) = 25.52
for SAF 2205 duplex stainless steel, and t8/5 is the cooling time
from 800 to 500 ◦ C in the weld thermal cycle. Since the peak tem-
peratures for welding speeds of 100, 150, and 200 mm/min were in
the range of 474–724 ◦ C, the direct calculation of Q from Eq. (4) is
not possible. However, if , , ω, P, and R in Eq. (3) are assumed to
be constant, then Q can be estimated for these welding conditions.
Table 2 lists the calculated heat inputs.
Fig. 3. Macro- and microstructures of FS weld showing various microstructural zones in SAF 2205 (600 rpm and 200 mm/min): (a) FS weld macrograph, (b) BM and (c)
SZ/TMAZ.
Table 3 The micrographs of the stir zones under the various FS welding
Chemical compositions of ˛ and in 2205 duplex stainless steel (wt%)
speed are shown in Fig. 4. It is evident that fine-grained ˛ and
Phases Cr Mo Ni Mn structure (microduplex structure) is formed in each condition.
Ferrite (˛) 24.30 2.98 5.07 0.85
In the case of duplex stainless steels, a refinement of matrix
Austenite () 20.78 1.75 7.78 1.67 phase and a uniform distribution of second phase are important to
improve mechanical properties, and especially to induce superplas-
ticity. In such alloys, a microduplex structure is usually obtained by
the proper thermo-mechanical processing (TMP). The typical TMP
Fig. 4. Optical microscope images showing the grain size in the stir zone at different welding speeds of (a) 50 mm/min, (b) 100 mm/min, (c) 150 mm/min, and (d) 200 mm/min.
266 T. Saeid et al. / Materials Science and Engineering A 496 (2008) 262–268
Fig. 5. (a) Pseudobinary diagram showing the 70% isoplethal section of the Fe–Cr–Ni phase diagram [34] and (b) the thermo-mechanical processing to obtain fine two-phase
structure in duplex stainless steel.
in the duplex stainless steel is to solution-treat the specimen at In friction stir welding of DSS, recently, Sato et al. [19] claimed
higher temperatures in ˛ single-phase region (Fig. 5), following by that when two phases exist in the structure, discontinuous dynamic
water-quenching (WQ) to obtain a supersaturated ˛ at room tem- recrystallization of austenite and continuous dynamic recrystalliza-
perature. The solution-treated specimen is then heavily cold-rolled tion of ferrite simultaneously occur in the SZ.
(CR : 70–90%) and finally aged at temperatures around 1000 ◦ C in ˛ Temperature measurements indicate the bottom surface under
and region. With this treatment, very fine particles are uni- the highest and lowest heat input conditions reached to the peak
formly precipitated [32]. temperatures of 849 and 474 ◦ C, respectively. On the other hand,
The obtained SZ microstructures reveal that FSW produces Fig. 5 suggests that the microstructure of duplex stainless steel does
microduplex structure in a relatively simple and single-step process not change to the fully ferritic structure when the steel is exposed
and potentially can be considered as an alternative to the time- to temperatures below 1300 ◦ C approximately. Therefore, under all
consuming and complicated TMP. Also, the results are motive to conditions of FSW encountered in this work, the SAF 2205 steel
use FSW in joining of microduplex stainless steels, without the risk plates were welded in the two-phase field of ˛ + . As such, it is
of grain growth, since weld zone grain growth is a very serious prob- likely that both continuous and discontinuous dynamic recrystal-
lem during fusion welding of usual duplex and microduplex grades lization mechanisms resulted in generation of fine grains in the SZ
[1,33]. through the scenario described by Sato et al. [19].
It is well accepted that generation of fine and equiaxed grains in In addition, Fig. 4 demonstrates that, an increase in welding
the SZ is a result of dynamic recrystallization [14–19,24,29]. Accord- speed decreases the recrystallized grain size. It was found that the
ing to the general principles for recrystallization [35], dynamic approximate grain sizes at the center of the SZ welded under the
recrystallization may occur discontinuously (nucleation of new highest and lowest heat input conditions were 5 and 1 m, respec-
grains and growth by motion of high angle grain boundaries) tively, which were much smaller than that of the base metal.
or continuously (increasing misorientation of existing subgrain The influences of FSW parameters on the microstructure
boundaries due to absorption of dislocations). The operative mech- of aluminum alloys were studied by a number of investiga-
anism depends on the strain and strain rate histories, as well as tors [36–40]. It was noted that the recrystallized grain size
the stacking fault energy (SFE) of the material. For a given material, can be reduced by decreasing the ratio of tool rotational
higher stresses (or strains) and strain rates tend to promote discon- speed/welding speed or increasing the welding speed [38,39].
tinuous recrystallization. Moreover, materials with low SFE (such For example, Ma et al. [38] reported that decreasing the ratio
as austenitic stainless steels), generally undergo discontinuous of rotational speed/traverse speed from 400 rpm/102 mm/min to
dynamic recrystallization since the dislocations tend to dissoci- 350 rpm/152 mm/min resulted in a decrease in the recrystallized
ate making recovery more difficult. Materials with high SFE (such grain size from 7.5 to 3.8 m in 7075Al-T651. More recently, Cava-
as ferritic stainless steels), however, tend to undergo continuous liere et al. [39] observed a strong variation in the SZ mean grain size
dynamic recrystallization. of 6082Al by increasing the welding speed from 40 to 165 mm/min.
T. Saeid et al. / Materials Science and Engineering A 496 (2008) 262–268 267
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