A statistical analysis of rotary friction welding of steel with varying carbon in workpieces

Nowadays, friction-welding method is accepted in many industries, particularly for joining dissimilar materials as a mass production process. It is due to advantages like less material waste, low production time, and low energy expenditure in it. The effect of change in carbon contents in steel is studied experimentally in friction-welding process and a statistical model is developed. An experimental setup was designed and produced to achieve the process with equal diameter workpieces. Continuous/direct drive friction-welding process is chosen in which transition from friction to forging stage can be achieved automatically by applying a brake. In this experimentation, workpieces with different carbon in each were welded with workpieces having same carbon contents. Response surface methodology of design of experiment is used to analyze the results. Friction welding is carried out with change of speed, forging pressure, and carbon content while keeping other parameters as constant. Tensile strength and hardness variations were obtained and examined in the post-weld at the joint of workpieces. The optimum welding parameters for the joints were obtained. Mathematical equations in terms of each output parameter are then validated experimentally.

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