ESTABLISHING THE PROCESS PARAMETERS OF LINEAR FRICTION WELDING PROCESS FOR DISSIMILAR JOINTS

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International Journal of Mechanical Engineering and Technology (IJMET)
Volume 10, Issue 06, June 2019, pp. 01-10. Article ID: IJMET_10_06_001
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=6
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication
ESTABLISHING THE PROCESS PARAMETERS
OF LINEAR FRICTION WELDING PROCESS
FOR DISSIMILAR JOINTS
G. Magudeeswaran, P. Rajapandiyan
Department of Mechanical Engineering, PSNA College of Engineering and Technology,
Kothandaraman Nagar, Muthanampatti, Dindigul, Tamilnadu, India
V. Balasubramanian and P. Sivaraj
Centre for Materials Joining & Research, Department of Manufacturing Engineering,
Annamalai University, Annamalai Nagar, Tamil Nadu, India
ABSTRACT
An attempt has been made to join Duplex stainless steel and Mild steel (MS) using
Linear Friction welding (LFW) process. In this investigation Finite element analysis
(FEM) was carried on a square butt joint configuration for various conditions. The
process parameters chosen are friction load, forging load, friction time, forging time
and frequency. Among the above-mentioned process parameters, friction force alone
was varied as it was found to be more significant to obtain a good bonding. The FEM
analysis revealed that 500 N of friction load imparted minimum deformation and in real
time experimentation a good bonding was established.
Keywords: Duplex stainless steel, Mild steel and Linear Friction welding.
Cite this Article: G. Magudeeswaran, P. Rajapandiyan, V. Balasubramanian and P.
Sivaraj, Establishing the Process Parameters of Linear Friction Welding Process for
Dissimilar Joints, International Journal of Mechanical Engineering and Technology,
10(6), 2019, pp. 01-10.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=6
1. INTRODUCTION
1.1. Dissimilar joints
Dissimilar materials are considered to be creative new structures or parts with tailor engineered
services. Sometimes a part needs high-temperature resistance in one area good corrosion
resistance in another. Structures may need toughness or wear resistance in one area combined
with high strength in another location which leads to dissimilar structural integrity. Hence,
joining dissimilar materials is often more difficult than joining the similar material or alloys
with minor differences in composition. Many dissimilar materials can be joined successfully
with the appropriate joining process and specialized joining procedures. Dissimilar joints are
widely used in automotive structures, pump industries, medical instrumentations, consumer

Establishing the Process Parameters of Linear Friction Welding Process for Dissimilar Joints
devices, and many other manufacturing and industrial applications. However, dissimilar joining
is more complicated in alloys like stainless steel and it much more complicated in multi phased
stainless steels like Duplex stainless steel, super duplex stainless steel and high nitrogen alloyed
stainless steel. [1, 2]
1.2. Joining issues in DSS
Duplex stainless steel (DSS) consists of equal proportions of ferrite and austenite not stabilize
in arc welding process. During arc welding of DSS inter metallic components are formed and
they degrade the performance of the joints. Hence, welding consumables are selected to create
the proper phase balance in the weld deposit and provide corrosion resistance at least equal to
that the base metal. Nickel content is often boosted in nominally matching filler metals in order
to promote austenite formation during the rapid cooling associated with welding. One such filler
metals 2209 contains nominally used for base metal 2205 [3]. The joint integrity of the DSS
welds are defined by their respective heat input, cooling rate, weld oxide formation, sigma
phase formation in weld metal and base metal during the process of welding. All the above-
mentioned issues can be minimized by imparting solid state method for joining DSS instead of
fusion welding process. [4]
1.3. Dissimilar joining of DSS
The welding of dissimilar metals considered difficult, due to the differences in the physical
properties of the two metals. Dissimilar metal welding (DMW) is frequently used to join duplex
stainless steels together or to other materials in different situations such as, gas pipeline and
petrochemical industry. Reasons for these combinations may be economic, property
considerations, transition or cladding. Stainless steels may be involved in joints of varying
degrees of dissimilarity [5, 6]. It is especially important to make an appropriate selection of
filler metal to produce a sound joint that will give satisfactory service performance. Generally,
to use benefits of both alloys, filler metals and welding process should be chosen precisely.
Accompanied by a good control of welding parameters, making it practical for welding
dissimilar weld joints. [7, 8]. However, solid state welding techniques may be suited for joining
DSS with other steels like mild steel. Among the joint configurations butt joints are most
effectively used for various structural applications. Butt joining of Dissimilar DSS joints with
other carbon alloys like mild steel (MS) may be carried out by two welding process namely
friction stir welding and linear friction welding. Although Friction stir welding has many
advantages over linear friction welding, the tool making process for joining DSS with mild steel
is a hard task. Hence, the linear friction welding (LFW) can be used to fabricate dissimilar joints
of DSS and MS.
Thus, the main objective of this research work is to optimize the process parameters for
fabricating dissimilar joints of DSS and MS by Finite Element Analysis and real time
experimentation. A brief illustration of the LFW process is described in the subsequent section.
2. LINEAR FRICTION WELDING
2.1. Principle
Linear friction welding (LFW) is a solid state joining process in which a stationary part is forced
against a part that is reciprocating in a linear manner in order to generate frictional heat .The
heat. Along with the force applied perpendicular to the weld interface, causes material at the
interface to deform and plasticize. Much of this plasticized material is removed from the weld,
as flash, because of the combined action of the applied force and part movement. Surface-oxides

G. Magudeeswaran, P. Rajapandiyan, V. Balasubramanian and P. Sivaraj
and other impurities are removed, along with the plasticized material, and this allows metal-to-
metal contact between parts and allows a joint to form. [11, 12]
Figure 1 Schematic diagram of the linear friction welding process
2.2. Linear Friction Welding Process Phases
Close examination of the LFW process reveals four distinct phases [13, 14]
Figure 2 Linear Friction Welding Process Phases
2.2.1. The Initial Phase
From the beginning the two workpieces are moving under pressure in a linear reciprocating
manner. Heat is generated at the rubbing interface due to solid friction. True surface contact
area increases throughout this phase due to wear and the thermal softening effects of movement.
No axial shortening of the specimens is experienced at this stage. This phase is critical for the
rest of process to proceed, for if insufficient heat is generated the next phase will not follow.
2.2.2. Transition Phase
During this very short period, the heat affected zone expands from the asperities into the bulk
of the material until phase III is reached. The true contact area is considered to be 100% of the
cross-sectional area due to wear and localized yielding of the asperities. A plasticized layer is
formed between the two rubbing surfaces which cannot support the axial load, thus deforming
permanently.
2.2.3. Equilibrium Phase
Axial shortening begins to register as plasticized matter is expelled into an upset. Material in
the heat affected zone that has yielded moves out of the rubbing interface aided by oscillatory
movement. This forms a flash, which may take different shape and size depending on the
material extruded. Melting conditions at the interface are not reached as experimental data have
shown. The phase is termed “equilibrium” to reflect the fact that as long as oscillation occurs
axial shortening increases while not leading automatically to another phase.

2.2.4. Deceleration/Forging Phase.
When the desired upset is reached the two materials are brought to rest very rapidly and a
forging pressure may be applied to consolidate the weld. The process is self-regulating as the
appropriate choice of process parameters (amplitude of oscillation, frequency of oscillation,
friction pressure) leads to phase III, which is necessary to be present to form sound welds.
Depending on the machine used the process is controlled by the length of axial shortening
achieved or process time, producing with excellent repeatability good joints. Joining may occur
at a different phase of the process (III or IV) depending on the material.
3. METHODOLOGY OF DISSIMILAR JOINING OF DSS AND MS
The plan of investigation for optimization of process parameters of Dissimilar joining of DSS
and MS is illustrated in the following stages:
Stage 1- Dissimilar Material selection based on need and applications
Stage 2 – Joint configuration
Stage 3 – Identifying the predominant process parameters in LFW
Stage 4 – Oscillating plate and stationary plate selection for process LFW of DSS and MS
Stage 5 – Assumptions in FEM analysis of dissimilar joining of DSS and MS
Stage 6 – Fixing the range of the process parameters to obtain good joint
Stage 7 – Analysis of good joint
Stage 8 – Results and Discussion
3.1. Dissimilar Material selection based on need and applications
3.1.1. Duplex stainless steel
DSS are made of austenite and ferrite microstructures. The structure of duplex stainless steels
has almost equal parts of these phases after proper heat treatment. There are several advantages
of this steel grade compare to general stainless steels. DSS also have twice of the yield strengths
compare to that of austenitic grades while holding worthy ductility and toughness. The thermal
expansion coefficient and the heat transfer properties of the DSS are intermediate between its
constituent. [18, 19]
3.1.2. Mild steel
Mild steel (MS) is a class of low carbon steel is very much suitable as structural steel. MS is
the only grade of steel which is very often used for conventional domestic application because
of properties and its low cost. Good machinability and excellent weldablity paves way for using
MS in various applications especially in automobile industries [21, 22]. The, mechanical,
physical properties and chemical composition of DSS and MS are illustrated in Tables 1, 2 and
3 respectively.
Table 1 Mechanical properties of DSS and MS
Description DSS MS
Tensile strength (MPa) 620 370
Yield strength (MPa) 450 247
Elongation (%) 25 15
Hardness (HRB) 106 120

Table 2 Physical properties of DSS and MS
Description DSS MILD STEEL
Density 7.805(g.cm³) 7.8-7.97g/cc
Modulus of Elasticity (GPa) 200 205
Electrical Resistivity 0.085x10-6(
𝛺. 𝑚) 0.0000159 Ω-cm
Thermal conductivity(W/m.K) 19 at 100ºC 46 at 25 ºC
Thermal Expansion(m/m.K) 13.7x10-6
to 100°C 11.7
Table 3 Chemical composition of DSS and MS
Material C Mn P S Si Cr Ni Mo Fe
DSS 0.03 2.0 0.03 0.02 1.0 21-23 4.5-6.5 2.5-3.5 Bal
Mildsteel 0.16-0.18 0.70-0.90 0.04 0.04 0.40 - - - Bal
3.2. Joint configuration
Two plates of each DSS and MS of length: 55mm, width: 30mm and thickness: 6mm is used
for fabricating the dissimilar joints of the same. Square Butt joint configuration as illustrated in
Fig.3
Figure 3 Joint configuration
3.3. Identifying the predominant process parameters in LFW
The important predominant process parameters of LFW are listed as follows:
1. Oscillation frequency
2. Frictional load
3. Forging load
4. Friction time
5. Forging time
Of all the above process parameters Friction force (the force used to help consolidate the
weld post-oscillatory motion) is very much significance for bonding characteristics of LFW
[24].
3.4. Oscillating plate and stationary plate selection for process LFW of DSS and
MS
In linear friction welding process one end to be fixed and another end to movable it’s also
connected with cam. If DSS plate is made to oscillate over the MS plate, and when the forging
and the frictional force are applied, it will cause buckling and will cause breaking of MS plate.

Hence, the high strength DSS plate is to be fixed and the low strength MS plate is be oscillated
over the DSS to cause frictional force which will lead to bonding of the two plates [26].
3.5. Assumptions in FEM analysis of dissimilar joining of DSS and MS
For precise simulation of LFW, a 3D model was developed using software. Since LFW process
involves friction and sliding forces and it’s necessary to carryout structural analysis for various
conditions using different parameters. Finite element analysis in its broadest sense is a method
of analysis that can be applied to solving differential equations, heat transfer problems, and
structural analysis problems. However, in this study, only structural analysis was carried out by
creating a model for the joint configuration as show in the Fig.3.The basic assumption to be
incorporated in analyzing the dissimilar joints in this investigation is that a good is obtained
when the total deformation in both the plates are to be minimum when the process parameters
are used [25]. The basic aim of this investigation is to obtain the best optimal process parameters
to impart the minimum deformation to get a good joint.
3.6. Range of the process parameters to obtain good joint
The process parameters for joining DSS and MS by using LFW process is presented in Table
4. In this investigation Friction load, which is the predominant process parameter of LFW
process and responsible factor for bonding is alone varied. All other parameters are maintained
constant as their combined influence was not much significant factor for bonding. However,
the parameters like frequency, forging time, friction time and forging load have their individual
effect on the performance of the joints fabricated by LFW.
Table 4 Range of the process parameters selected
Parameters Unit Trial 1 Trial 2 Trial 3 Trial 4 Trial 5
Friction load N 300 400 500 600 800
Friction time Sec 30 30 30 30 30
Forging load N 200 200 200 200 200
Forging time Sec 3 3 3 3 3
Frequency Hz 30 30 30 30 30
3.7. Analysis of good joint
3.7.1. FEM analysis
Catia v5 software was used to carry out a 3D modeling of LFW joint configuration as shown in
Fig 3 with 255 nodes and 736 elements. Structural analysis was carried out by choosing applied
frictional force and forging force as required by the LFW process by varying the friction load
for each trials as detailed in Table 4. A set of 5 trails was conducted by FEM analysis and the
deformation characteristics of each trail is displayed in Figs. 4-8. The estimated strain for each
trail is presented in Table 5 and the minimum deformation is obtained in trial and is expected
to have a good bonding when compared to other trails [27].

Figure 4 Trial-1 Applied friction load at 300N Figure 5 Trial-2 Applied friction load at 400N
Figure 6 Trial-3 Applied friction load at 500N Figure 7 Trial-4 Applied friction load at 600N
Figure 8 Trial-4 Applied friction load at 800N
Table 5 Deformation (Strain) value of joints
Parameters Trial 1 Trial 2 Trial 3 Trial 4 Trial 5
Deformation 9.6 x10-5
1.2 x10-4
8.0x10-5
1.9 x10-4
2.5 x10-4
3.7.2. Experimental analysis
LFW involves joining of materials through the relative motion of two components undergoing
an axial force. The friction between the rubbing surfaces coupled with the strong applied
pressure heats up the materials and creates the necessary conditions in the contact zone to soften
the individual components and to form metallic bonds. When welding is obtained by forcing a
stationary part against a part that is reciprocating in a linear manner. A real time LFW was
carried out to fabricate dissimilar joints of DSS and MS by using indigenously built LFW
machine for all the five trails for which FEM analysis was done. The observations of all five
trails are presented in Table 6. It is evident that Trail 3 is proven to impart a good bonding of
DSS and MS.

Table 6 LFW process of DSS and MS joints
Trials Side 1 Side 2 Observation
Trial 1 No fusion on both sides
Trial 2
Flash formation is more and
incomplete fusion
Trial 3
Good Fusion without flash and
buckling
Trial 4
Flash formation is less partly
incomplete fusion
Trial 5
Buckling with flash formation
and no fusion of the joint
3.8. Results and Discussion
LFW offers many advantages over traditional fusion welding methods, including excellent
mechanical properties avoidance of melting, allowing for a range of dissimilar materials to be
joined. The two plates DSS and Mild steel are initially positioned adjacent, in contact at the
intended weld interface. During the process, the MS oscillates against DSS and no buckling is
observed during the real time experimentation. A static forging load is applied on the DSS and
frictional force is exerted by the oscillation of MS plate over the DSS plate. It is evident that
all the other parameters in this investigation are maintained constant expect friction load. In this
investigation good bonding is obtained in Trail 3 where the frictional force is 500 N which is
neither too high nor too low. If the frictional force is too low no bonding is established and if
the friction force is too high flash formation along with incomplete fusion occurs. Thus, a
balance nominal friction force along with other established parameters aid in good bonding due
to minimum deformation and is evident in Trial 3.
Hence, it is proved that LFW process can also be used for fabricating the dissimilar butt
joint of DSS and MS. However, the structural integrity of the bonding have to be investigated
mechanically and metallurgical to apply LFW for fabrication of Dissimilar joints comprising
of DSS and MS.
4. CONCLUSION
1. LFW offers many advantages over traditional fusion welding methods, including
excellent mechanical properties avoidance of melting, allowing for a range of dissimilar
materials to be joined.
2. LFW is a very better process for fabricating Dissimilar butt joints of DSS and MS
3. A balance nominal friction force along with other established parameters aid in good
bonding of the dissimilar joint of DSS and MS due to minimum deformation.

ACKNOWLEDGEMENT
The authors are Thankful to Centre for Materials Joining & Research, Department of
Manufacturing Engineering, Annamalai University, Annamalai Nagar, 608002 Tamil Nadu,
India for providing welding facilty to carryout real time experimentation.
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