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Friction Stir Welding of Steel: Part Three :: Total Materia Article
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Friction Stir Welding of Steel: Part Three
Te article describes mechanical properties, weld integrity and microstructure of a low carbon steel and a low carbon 12% chromium alloy steel. In general, mechanical testing and metallographic examinations showed good properties and reasonably uniform shaped double-sided weld profiles with no evidence of buried defects.
W.M. Thomas, P.L. Threadgill and E.D. Nickolas
TWI Ltd, Cambridge, United Kingdom
Weld Integrity of Low Carbon 12%Chromium Alloy Steel
Cross-weld tensile tests recorded an ultimate tensile stress of around 539 to 541 N/mm2 with failure occurring in te parent metal well away from te joint or te HAZ region as shown in Figure 1. Acceptable transverse face and root bends (bends with first pass in tension and bends with second pass in tension), typically achieved 180°, see Figure 2.
Figure 1: Cross-weld tensile test samples (3 off weld surfaces machined to uniform thickness before testing 3 off as welded)
Figure 2: Typical bend test results in 12 mm thick alloy steel plate, showing parent metal, and first pass and second pass in tension
Metallographic examination of selected sections, typically as shown in Figure 6 (see Friction Stir Welding of Steel: Part Two) shows a reasonably uniform shaped double-sided weld profile with no evidence of buried defects.
Parent metal   -  158HV10
Weld Integrity of Low Carbon Steel
Te cross-weld tensile tests gave an ultimate tensile stress of around 453 to 457 N/mm with failure occurring in te parent metal well away from te joint or HAZ region, broken tensiles are shown in Figure 3. Transverse 180° side bend tests are shown in figure 14.
Figure 3: Tensile test specimens of carbon steel FSW butt welds, showing failure in te parent metal away from te weld and HAZ
Figure 4: Three 180° side bends in low carbon steel FSW butt joints, plus one comparison parent metal bend
Metallographic examination of selected revealed a flow configuration (see Figure 7 within Friction Stir Welding of Steel-Part Two) not unlike those found on certain aluminium alloy welds. A reasonable shaped weld profile no evidence of buried defects, but some tool wear debris was observed.
Parent metal   -  131HV10
Low carbon 12% Chromium Alloy steel
Te weld region exhibited two distinct microstructural zones. One of these is te central weld thermomechanically affected (TMAZ) zone, which had transformed, with associated recrystallisation and grain growth. On both sides of te (TMAZ) central weld zone a HAZ region showed some transformation close to te weld but showed no evidence of grain growth. Further out, towards te parent material, te HAZ still showed a degree of tempering, but had not transformed. Te HAZ zones on either side were similar in all features. Typical of this type of steel, te parent material showed a very fine ferritic/martensitic structure.
Within te TMAZ a range of ferrite and martensite structures had developed, a typical example is shown in Figure 5. Some light etching bands were present, towards te top of each weld pass. Energy dispersive x-ray micro analysis of these bands indicated te presence of some tool debris. Longitudinal weld sections, however, confirmed that no measurable reduction in weld depth had occurred after steady state welding conditions had been established. There was no evidence of buried defects within te weld region.
Figure 5: Microstructural bending in TMAZ weld region, showing banded two phase martensite and ferrit structure (12% chromium alloy steel weld)
Te microstructure of te parent steel consisted of te expected ferrite.pearlite grains. Te subcritical HAZ showed te expected spheroidization of pearlite, and te intercritical HAZ showed substantial grain refinement resulting from te partial transformation to austenite. Te higher temperature supercritical HAZ in te centre of te weld had transformed to a bainitic/ferritic microstructure, with no evidence for martensite transformation.
Te boundary between te HAZ, and te TMAZ (i.e. te point of which plastic deformation owing to te welding process first occurred) was difficult to identify, as no evidence of deformation without recrystalisation was observed. This suggests that te HAZ/TMAZ boundary occurred in te region heated above te AC3 temperature. This is in accordance with te peak temperature reached during friction stir welding of low carbon steel, which is probably around 1000-1100°C. A typical microstructure from te centre of te weld (in te TMAZ) is shown in Figure 6a, while Figure 6b shows te HAZ in te region of te AC3 isotherm, where areas of partial and complete transformation to austenite during te welding cycle are apparent.
Figure 6a: Banding between partially and completely transformed HAZ in friction stir welding in low carbon steel
Figure 6b: Microstructure of centre of friction stir weld in low carbon steel
Unlike te 12% chromium alloy steel, there was some evidence of tool debris within te weld region of te carbon steel examined, although examination of te tool after welding showed little wear. Te debris existed as fine inclusions, exerting no apparent on te microstructure of te weld. It is needed.
Te parent hardness of about 131 HV10 increases across te weld to a maximum of 160HV at te centre. These low values suggest te material was in te hot rolled condition before welding.
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Friction Stir Welding of Steel: Part One
Friction Stir Welding of Steel: Part Two
Friction Stir Welding of Steel: Part Four
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