Controlling the toughness of the interface zone of welded joints of dissimilar 32G2 and 10Kh11N23T3MR steels during rotary friction welding

Cover Page

Cite item

Full Text

Abstract

Problem. Despite numerous studies on the problems of rotary friction welding of dissimilar materials, there is a lack of data on the influence of welding parameters on the formation of brittle phases in the mating zone of carbon and austenitic steels, which affect the structural strength of the joints. Aim. The objective of this study is to evaluate the influence of the friction force on the impact toughness of the mating zone of welded joints made of 32G2 and 10Kh11N23T3MR steels. Methods. Welded hollow cylindrical workpieces made of these steels with an outer diameter of 73 mm and a wall thickness of 12 mm were performed with friction force varying from 70 kN to 210 kN. The remaining parameters were held constant: forging force of 280 kN, friction speed of 600 rpm, upsetting during heating of 6 mm, and forging time of 3 s. Optical and scanning electron microscopy with EBSD and X-ray spectral analysis were used to study the microstructure of welded joints. Impact toughness tests were conducted on specimens with a V-shaped stress concentrator in the joint zone at room temperature. A detailed factual analysis of the fractured specimens was conducted, including an analysis of the chemical composition of individual characteristic areas with distinct fracture morphologies. Results. It was established that the presence of a titanium carbide phase, which forms in the joint zone during diffusion of elements during welding, leads to embrittlement of the joint and a decrease in impact toughness. Reducing the heating force to 70 kN increases the volume of metal extruded during forging, effectively removing the brittle phase and ensuring toughness in the joint zone comparable to that of austenitic steel. Conclusions. The obtained results demonstrated the fundamental possibility of producing joints from 32G2 and 10Kh11N23M3TR steels, which have high viscosity, are of practical interest and can be useful in developing technological modes for welding electric motor shafts and turbocharger rotors.

About the authors

Elena Y. Priymak

JSC “ZBO Drill Industries Inc”; Orenburg State University named after V.A. Bondarenko

Email: elena-pijjmak@yandex.ru
ORCID iD: 0000-0002-4571-2410

PhD (Engineering), Associate Professor,
Head of the laboratory of metal science and heat treatment,
senior researcher at the Research and education center for new materials and advanced technologies.

Russian Federation, 460026, Russia, Orenburg Oblast, Orenburg, Prospekt Pobedy, 118.; 460018, Russia, Orenburg, Prospekt Pobedy, 13.

Yaroslav S. Syomka

Orenburg State University named after V.A. Bondarenko

Email: semkazbo@bk.ru

postgraduate student,
researcher at the Research and Education Center for New Materials and Advanced Technologies. 

Russian Federation, 460018, Russia, Orenburg, Prospekt Pobedy, 13.

Sergey V. Kamenev

Orenburg State University named after V.A. Bondarenko

Email: kamenev_sergey@mail.ru
ORCID iD: 0000-0003-4333-3123

PhD (Engineering), Associate Professor,
assistant professor of Chair of Mechanical Engineering Technology,
Metalworking Machines and Complexes.

Russian Federation, 460018, Russia, Orenburg, Prospekt Pobedy, 13.

Danila S. Paramonov

Orenburg State University named after V.A. Bondarenko

Author for correspondence.
Email: dsparam@mail.ru

postgraduate student, 
senior lecturer of Chair of Production Technologies for Material Processing.

Russian Federation, 460018, Russia, Orenburg, Prospekt Pobedy, 13.

Irina L. Yakovleva

M.N. Mikheev Institute of Metal Physics of the Ural Branch of RAS

Email: labmet@imp.uran.ru
ORCID iD: 0000-0001-8918-3066

Doctor of Sciences (Engineering),
chief researcher at the Physical Metallurgy Laboratory.

Russian Federation, 620108, Russia, Yekaterinburg, Sofya Kovalevskaya Street, 18.

References

  1. Meena P., Anant R. Residual stress mitigation in dissimilar T/P92 and AISI304L steel multi-pass weld joint using ER308L and ERNiCrMo-3 (IN625) fillers: simulation and experimental approach. Welding in the World, 2025, vol. 69, no. 10, pp. 1–34. doi: 10.1007/s40194-025-02170-8.
  2. Jihua Liu, Shitao Chen, Runting Zheng, Junjie Ou, Weijian Yang, Peng Li, Chenggang He, Ruxin Yu. Investigation of the Microstructures and Fracture Failure Mechanisms of Metal Active Gas Welded Joints of Dissimilar 304 Stainless Steels and Q235B/Q345 Low-Carbon Steels. Journal of Materials Engineering and Performance, 2025, vol. 34, pp. 20708–20718. doi: 10.1007/s11665-025-10694-9.
  3. Jiecai Feng, Longhui Tao, Hongfei Liu, Chuanwan Luo, Jinping Liu, Yilian Zhang, Meng Jiang, Xi Chen, Yingzhong Tian. Microstructure and Mechanical Properties of Dissimilar Metal Welded Joints for Nuclear Applications Using Laser Welding with Dissimilar Filler Wire Addition. Metals and Materials International, 2025, vol. 31, no. 7, pp. 1–10. doi: 10.1007/s12540-025-01996-7.
  4. Ul-Hamid A., Tawancy H.M., Abbas N.M. Failure of weld joints between carbon steel pipe and 304 stainless steel elbows. Engineering Failure Analysis, 2005, vol. 12, no. 2, pp. 181–191. doi: 10.1016/j.engfailanal.2004.07.003.
  5. Venkatakrishna A., Lakshminarayanan A., Vasantharaja P., Vasudevan M. Decisive impact of Filler-free joining processes on the Microstructural evolution, tensile and impact properties of 9Cr-1Mo-V-Nb to 316 L(N) dissimilar joints. Proceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science, 2021, vol. 236, no. 5, pp. 2408–2427. doi: 10.1177/09544062211029307.
  6. Sunilkumar D., Muthukumaran S., Vasudevan M., Reddy M.G. Effect of friction stir and activated-GTA welding processes on the 9Cr–1Mo steel to 316LN stainless steel dissimilar weld joints. Science and Technology of Welding and Joining, 2020, vol. 25, no. 4, pp. 311–319. doi: 10.1080/13621718.2019.1695347.
  7. Sunilkumar D., Mathew J., Muthukumaran S., Vasudevan M. Friction Stir Welding of 2.25Cr-1Mo Steel to AISI 316LN Stainless Steel. Transactions of the Indian Institute of Metals, 2020, vol. 73, pp. 1689–1693. doi: 10.1007/s12666-020-01984-y.
  8. Wenya Li, Vairis A., Preuss M., Tiejun Ma. Linear and Rotary Friction Welding Review. International Materials Reviews, 2016, vol. 61, no. 2, pp. 71–100. doi: 10.1080/09506608.2015.1109214.
  9. Farbakhti M., Elmi Hosseini S.R., Mohammadi S.A.M., Sadatabhari S., Huo Yuan-ming, Ruifeng Li. Similar and Dissimilar Rotary Friction Welding of Steels: A Review of Microstructural Evolution and Mechanical Properties. Journal of Materials Research and Technology, 2025, vol. 36, pp. 8777–8803. doi: 10.1016/j.jmrt.2025.05.079.
  10. Hong Ma, Guoliang Qin, Peihao Geng, Fei Li, Banglong Fu, Xiangmeng Meng. Microstructure characterization and properties of carbon steel to stainless steel dissimilar metal joint made by friction welding. Materials and Design, 2015, vol. 86, pp. 587–597. doi: 10.1016/j.matdes.2015.07.068.
  11. Balalan Z., Yaz M., Ekinci O., Buldag S. Microstructure and mechanical properties of friction welded dissimilar AISI 1040 and AISI 304 steels. Materials Testing, 2025, vol. 67, no. 2, pp. 199–210. doi: 10.1515/mt-2024-0156.
  12. Banerjee A., Ntovas M., Laurie Da Silva, Rahimi S. Microstructure and mechanical properties of dissimilar inertia friction welded 316L stainless steel to A516 ferritic steel for potential applications in nuclear reactors. Manufacturing Letters, 2022, vol. 33, pp. 33–37. doi: 10.1016/j.mfglet.2022.07.002.
  13. Paventhan R., Lakshminarayanan P., Balasubramanian V. Fatigue behavior of friction welded medium carbon steel, Fatigue behaviour of friction welded medium carbon steel and austenitic stainless steel dissimilar joints. Materials & Design, 2011, vol. 32, no. 4, pp. 1888–1894. doi: 10.1016/j.matdes.2010.12.011.
  14. Kurt B. The interface morphology of diffusion bonded dissimilar stainless steel and medium carbon steel couples. Journal of Materials Processing Technology, 2007, vol. 190, no. 1-3, pp. 138–141. doi: 10.1016/j.jmatprotec.2007.03.063.
  15. Jatavallabhula J.K., Satyanarayana V.V., Reddy G.S., Baridula R.R., Pappula B. Intelligent prediction of notch tensile strength in friction welded dissimilar stainless steel joints using machine learning. International Journal on Interactive Design and Manufacturing, 2026, vol. 20, pp. 265–283. doi: 10.1007/s12008-025-02385-5.
  16. Belkahla Y., Mazouzi A., Lebouachera S.E.I., Hassan A.J., Fides M., Hvizdos P., Cheniti B., Miroud D. Rotary friction welded C45 to 16NiCr6 steel rods: statistical optimization coupled to mechanical and microstructure approaches. International Journal of Advanced Manufacturing Technology, 2021, vol. 116, pp. 2285–2298. doi: 10.1007/s00170-021-07597-z.
  17. Ananthapadmanaban D., Seshagiri Rao V., Abraham N., Prasad Rao K. A study of mechanical properties of friction welded mild steel to stainless steel joints. Materials & Design, 2009, vol. 30, no. 7, pp. 2642–2646. doi: 10.1016/j.matdes.2008.10.030.
  18. Firmanto H., Candra S., Hadiyat M.A., Triastomo Y.P., Wirawan I. Tensile strength and microstructure of rotary-friction-welded carbon-steel and stainless-steel joints. Journal of Manufacturing and Materials Processing, 2022, vol. 7, no. 1, article number 7. doi: 10.3390/jmmp7010007.
  19. Anderson T.L. Fracture Mechanics: Fundamentals and Applications. 4th ed. USA, CRC Press Publ., 2017. 684 p. doi: 10.1201/9781315370293.
  20. Banerjee A., da Silva L., Rahimi S. Finite element modelling of transient behaviours and microstructural evolution during dissimilar rotary friction welding of 316 austenitic stainless steel to A516 ferritic steel. Journal of Advanced Joining Processes, 2023, vol. 8, article number 100167. doi: 10.1016/j.jajp.2023.100167.
  21. Peihao Geng, Guoliang Qin, Jun Zhou. Numerical and experimental investigation on friction welding of austenite stainless steel and middle carbon steel. Journal of Manufacturing Processes, 2019, vol. 47, pp. 83–97. doi: 10.1016/j.jmapro.2019.09.016.
  22. Montheillet F. Dynamic Recrystallization Behaviours in Metals and Alloys. Materials, 2023, vol. 16, no. 3, article number 976. doi: 10.3390/ma16030976.
  23. Lalvani H., Mandal P., Yaghi A., Santos P., Baufeld B. A solid-state joining approach to manufacture of transition joints for high integrity applications. Journal of Manufacturing Processes, 2022, vol. 73, pp. 90–111. doi: 10.1016/j.jmapro.2021.10.058.
  24. Das R., Sivaswamy G., Lalvani H., Singh A.P. Fracture toughness and microstructural analysis of rotary friction welded S355J2 and SS316L steels for critical applications. Journal of Advanced Joining Processes, 2024, vol. 10, article number 100244. doi: 10.1016/j.jajp.2024.100244.

Supplementary files

Supplementary Files
Action
1. JATS XML
Download

Copyright (c) 2026 Priymak E.Y., Syomka Y.S., Kamenev S.V., Paramonov D.S., Yakovleva I.L.

Creative Commons License
This work is licensed under a Creative Commons Attribution 4.0 International License.