Producing dual-phase microstructure in friction stir welding/processing of

medium carbon low alloy steels

*
Md. Anwar Ali Anshari, Murshid Imam
*Department of Mechanical Engineering, Indian Institute of Technology Patna (IITP), Bihta-
801106
Abstract: Microstructural evolution in steels during friction stir welding (FSW)/friction stir
processing (FSP) is a more complex process than that in aluminium alloys due to the
occurrence of phase transformations. The dominant parameters of thermal cycle that affect
the microstructural evolution are peak temperature and cooling rate. In the present work,
critical control of the welding conditions produced a fine ferrite–martensite/bainite duplex
structure with varying volume fractions of martensite/bainite and ferrite within the stir zone.
The developed microstructure provides the preferable combination of tensile strength and
ductility. The findings were achieved to clarify the effect of the welding parameters on the
weldability. Additionally, process window is constructed to show the correlation between the
range of welding parameters and the optimum condition of dual phase microstructure
distributions. It is shown that FSW/FSP can be an effective tool for the development of dual
phase steels which can offer an outstanding combination of strength and drawability as a
result of their high combination of strength and ductility, as well as their high strain
hardenability which gives them good strain redistribution capacity.
Keywords: Duplex structures, Drawability, Hardness, grain structure, Strain hardenability

Introduction
Better combination of strength and ductility is center of focus for automobile, aerospace and
military applications. Duplex phase steels and ultrafine grained steels show better strength as
well as ductility. Friction stir processing is one of the emerging techniques with immense
potential to change the microstructure and grain size to give improved yield strength as
reported by many researchers [1]. It was primarily developed for aluminium/Al-alloys
because of its low melting points [2]. Itis a technique developed at ‘The Welding Institute’ in
UK in 1991. After commercial success in FSW/P of Aluminium and its alloys, it was applied
to medium and high strength alloys also. Applicability of FSW for high strength steels was
reported by Matsushita Muneo by successful FS-welding of steels having the strength in the
range of 590 to 1 180 N • mm−2. Report states sound and defect free weld but negligible
change in tensile strength [3]. Fujii et al. reported the relationship between the microstructure
of weld and welding parameters including the effect of cooling rates and peak temperatures
for steels of different carbon content. The study included the steels from IF to S45C which
introduced the significant effect of carbon content on microstructure and strength [4]. Study
on the effect of welding parameters on microstructure and strength reported the dual phase
formation as it happens when the peak temperature goes in between A1 and A3
transformation lines [5]. It is fact that the peak temperatures are the function of rotational and
traverse speed of the tool.L. Y. WEI et al. showed a linear relation between heat input and
grain sizes of phases like ferrite and bainite formed in FSW of HSLA65[6]. Gladys Perez
Medina et al. depicted the effect of cooling rate on the micro-structural evolution i.e. the
formation of relatively increased amount of martensite on rapid cooling during FSW of
TRIP-780 steel [7]. On the basis of FS welding parametric analysis, a study by Vasanth C.
Shunmugasamyet al. reported 1200 rpm and 60 mm/min traverse speed as optimum for AISI
1006 low-carbon steel but with decreased strength and strain. The study introduced the effect
of annealing of welded samples with improved strength and ductility both [8].HoonHwecho
et al. reported the effect of FSW on grain size refinement in ferritic steel. Dynamic
recrystallization as a result of severe shear deformation and high temperatures during FSW
was mentioned as the main cause of refinement [9]. A study on the formability of ferritic
steel processed by FS technique showed a drastic change in size of ferritic grains which is
from25 to 3µm. It resulted significant increase in tensile and yield strength both [10]. This is
because of the severe plastic and shear deformation ability of FS processing technique.
According to study done by Scott Anthony Rose, the effect of cooling rate plays significant
role on grain size and microstructure evolution. The study reports that the increasing cooling
rate decreases grain size and a cooling rate faster than 200C produces harder phase namely
bainite in case of FS welding of high strength low alloy steels [11]. Working on SAF2507
steel, Sato et al. also reported high quality weld with improved strength in the stir zone.
Significant refinement of ferrite and austenite happened during FSW due to dynamic
recrystallization [12].
This work deals with the development of dual phase in high strength
low alloy steel namely EN-8 steel by FS processing technique. This steel is known for its
improved strength over mild steel and so is very useful for automotive industries. As FSP has
ability to refine microstructure as well as grain, it is a good option to adopt for material
processing. According to Hall-Petch relation, smaller is the grain size, higher will be the
number of grain boundary. The grain boundaries are a significant parameter to effect the
plastic deformation in the initial stage of deformation [13].Hence yield strength gets
improved. On the other hand, microstructure is also very important to describe the strength
and ductility of materials. Depending on the cooling rate during FSP, it is possible to control
the combination of phases such as Ferrite plus Pearlite/Bainite/Martensite which give a
variety of strength and ductility combination. It is clear from the study of Imam et al. on FSW
of S45C with cooling /without cooling i.e. the formation of phases like lath martensite on the
top and Ferrite plus Pearlite on the bottom depending on temperature gradient [14].

Experimental procedures
In this work, EN-8 steel plate having chemical composition shown in table-1 was used. The
dimension taken for FS processing was 200×100×2 (lbt) in mm. Processing was done with
WC tool having the dimensions as mentioned in table-2. Processing was done at constant
transverse velocity of 200mm/min and two different rotational speed of 400 and 500rpm.
Material was well processed without defect.
Samples for characterization were cut from processed zone by Wire-EDM. It was subjected
to optical microscopy, Scanning electron microscopy and micro-hardness testing. Each
sample was polished with lower to higher grades of emery paper followed by polishing with
diamond paste for better finishing of polished surface. For SEM and optical microscopy,
polished surface was etched with 2% nital solution for clear observation of grains, grain
boundaries and phase determination.The processing schematic can be seen clearly in fig-1.
After microstructural analysis, it was subjected to check the mechanical behavior. In this
regard, sample was tested for its micro hardness at 200g load with a dwell time of 10
seconds.

Table 1:Chamical composition of EN-8 steel

Work Material C Si Mn S P Fe
EN-8 steel 0.4% 0.25% 0.80% 0.05% 0.05% Rest

Table 2: Tool geometry

Tool material Shoulder dia (mm) Pin length Pin profile/dia (mm)
WC (Tungsten carbide) 15 1.5 Cylindrical/4
Results and discussions
The optical micrograph of throughout cross
cross-section
section of processed material in fig-2
fig shows
successful
ssful processing without defect
defects like voids, tunneling effect etc.. This ensures the
processing parametes selected is under the optimum condition. There is clear evidence of
transision zone

SZ

Fig-1:
1: The schematic of friction stir processing

SZ
TMA
TMAZ
BM HAZ
1000µm

Fig-2: The optical icrograph of through cross-section

section of processed material

from stir zone (SZ) to heat affected zone (HAZ) with a thin strip. The fig-33 is an optical
micrograph which shows the refinement of material in the stir zone as the grains in the stir
zone are far smaller than grains in the base material. It is because of the severe plastic
deformation of material due to high heat generation and shearing action of rotating

P
SZ
F

BM
5µm

tool.Further analysis-
Fig-3/4: Optical micrograph/SEM
SEM image of processed material from left to right respectively

By SEM, the image shown in fig-4,

fig 4, confirms the formation of duplex phase as a combi
combination
of ferrite plus pearlite. There are colonies of pearlites of different sizes. The formation of
pearlite also ensures the temperature rise above A1 transformation line where carbon
dissolves and austenite is formed. On the basis of cooling rate different phases form. Some
pearlite lamellas have smaller while some have larger interspacing and it is because of
different cooling
rates. Some smaller pearlite grains are also there which induce pinning effect and thus
strength is improved. The fraction of pearlite in final stirred zone is significant which is the
reason of improvement in strength [15]. Hardness profile shown in the fig-5 shows maximum
hardness value for processing parameters of 500rpm and 200 mm/min and thus it ensures it as
optimum condition. Improved hardness signifies the enhanced mechanical property by FS
processing technique. This is because of the dual phase formation i.e. combination of ferrite
and pearlite.

Conclusion
Based on this study, it is clear that FS processing is an efficient technique to produce dual
phase microstructure in EN-8 steel. The distribution of smaller pearlites causing the pinning
effect and significant fraction of pearlites improve the strength. The conclusions can be
summarized

as:
1.Different speeds 400 and 500
rpm with a constant transverse
velocity of 200mm/min were
used as inputs and among them
500 rpm was optimum forthe
processing conditions.
2. Pearlites formed at different
orientation as visible in the SEM
image contribute in
resistanceagainst deformation.

Fig-5: Hardness plot of processed material

Fig-5: Hardness vs distance from center of SZ

Acknowledgement
Authors thank to Mechanical engineering department of IIT BHU for providing facility of
Friction stir welding machine for processing and sincere thanks to all staffs of department of
Mechanical engineering of IITP (Indian Institute of technology Patna) for their help and
support in characterization of processed material.

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