Friction Hydro-Pillar Processing of a High Carbon Steel: Joint Structure and Properties

• Published in: Metallurgical and materials transactions. B, Process metallurgy and materials processing science Vol. 49; no. 2; pp. 699 - 708
• Main Authors: Kanan, Luis Fernando, Vicharapu, Buchibabu, Bueno, Antonio Fernando Burkert, Clarke, Thomas, De, Amitava
• Format: Journal Article
• Language: English
• Published: New York Springer US 01-04-2018; Springer Nature B.V
• Subjects: CARBON STEELS; Characterization and Evaluation of Materials; Chemistry and Materials Science; CRACKS; DEFECTS; Deformation effects; FASTENERS; FRICTION; HEAT; Heat generation; HEATING; High carbon steels; High strength steels; JOINING; MATERIALS SCIENCE; Metallic Materials; Metallurgy; Nanotechnology; Plastic deformation; Plastic flow; PLASTICITY; PROCESSING; ROTATION; SOLIDS; Steel structures; Structural Materials; Surfaces and Interfaces; Temperature distribution; Thin Films; WALLS; Higher Force Rates; Hole Crack; Greater Processing Time; Force Rate; Stud Force
• ISSN: 1073-5615; 1543-1916
• DOI: 10.1007/s11663-018-1171-5

A coupled experimental and theoretical study is reported here on friction hydro-pillar processing of AISI 4140 steel, which is a novel solid-state joining technique to repair and fill crack holes in thick-walled components by an external stud. The stud is rotated and forced to fill a crack hole by plastic flow. During the process, frictional heating occurs along the interface of the stud and the wall of crack hole leading to thermal softening of the stud that eases its plastic deformation. The effect of the stud force, its rotational speed and the total processing time on the rate of heat generation and resulting transient temperature field is therefore examined to correlate the processing variables with the joint structure and properties in a systematic and quantitative manner, which is currently scarce in the published literature. The results show that a gentler stud force rate and greater processing time can promote proper filling of the crack hole and facilitate a defect-free joint between the stud and original component.