Continuous Drive Friction Welding of AISI 8630 Low-Alloy Steel: Experimental Investigations on Microstructure Evolution and Mechanical Properties

Abstract Continuous drive friction welding (CDW) is a state-of-the-art solid-state technology for joining metallic components used in aerospace, oil and gas, power generation industries. This study summarizes the results of mechanical microstructural investigations on modified AISI-8630 steel subjected to CDW. The effects process parameters, including rotational speed, friction, forge forces, during CDW were explored determine an optimum condition. properties weld, characteristics across different regions weld measured examined. microstructure characterization suggest that zone (WZ) experiences temperatures above Ac3 thermo-mechanically affected (TMAZ) between Ac1 material. Investigations with electron backscatter diffraction (EBSD) demonstrated occurrence strain-induced dynamic recrystallization weld. higher yield ultimate tensile strengths at expense ductility hardening capacity compared base metal (BM). strain-hardening profiles welds exhibited dual-slope characteristic, indication levels plastic deformation experienced by constituent phases (i.e., martensite, bainite ferrite) present microstructure. maximum strength-to-ductility combination static toughness values obtained produced under highest force intermediate 1200–1400 rpm, 375–425 kN, 600–650 respectively.