Hattingh D.G., Bulbring D.L.H., Els-Botes A., James M.N.
Friction Processing Research Institute, Faculty of Engineering, The Built Environment and Information Technology, Nelson Mandela Metropolitan University, Port Elizabeth 6031, South Africa; School of Marine Science and Engineering, University of Plymouth, Drake Circus, Plymouth PL4 8AA, United Kingdom
Hattingh, D.G., Friction Processing Research Institute, Faculty of Engineering, The Built Environment and Information Technology, Nelson Mandela Metropolitan University, Port Elizabeth 6031, South Africa; Bulbring, D.L.H., Friction Processing Research Institute, Faculty of Engineering, The Built Environment and Information Technology, Nelson Mandela Metropolitan University, Port Elizabeth 6031, South Africa; Els-Botes, A., Friction Processing Research Institute, Faculty of Engineering, The Built Environment and Information Technology, Nelson Mandela Metropolitan University, Port Elizabeth 6031, South Africa; James, M.N., Friction Processing Research Institute, Faculty of Engineering, The Built Environment and Information Technology, Nelson Mandela Metropolitan University, Port Elizabeth 6031, South Africa, School of Marine Science and Engineering, University of Plymouth, Drake Circus, Plymouth PL4 8AA, United Kingdom
Friction taper stud welding is a new variant of friction welding which has been developed from the principles of friction hydro-pillar processing. This paper considers the effect of weld process parameters on weld defects, macrostructure and mechanical properties in AISI 4140 steel. It also presents 3D residual stress data for a typical friction taper stud weld. Applied downwards force, rotational speed and plunge depth (equivalent to consumable length) of the stud tool were systematically varied whilst measuring tool torque and temperature at several locations during welding. A simple Taguchi analysis was then used to relate process parameters and weld tensile strength. The combinations of parameters leading to high tensile strength are identified and linked to the occurrence of specific weld defects. © 2011 Elsevier Ltd.
AISI 4140 steel; D. Welding; E. Mechanical; Ferrous metals and alloys; High-tensile strength; Macrostructures; Measuring tools; Process parameters; Rotational speed; Taguchi analysis; Weld defects; Weld process; Defects; Electric welding; Friction; Iron; Mechanical properties; Metallurgy; Steel sheet; Stud welding; Studs (fasteners); Studs (structural members); Tribology; Welds; Tensile strength