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<p>This study investigates the influence of continuous drive rotary friction welding (CDFW) parameters on the metallurgical and mechanical integrity of dissimilar joints between Duplex Stainless Steel (DSS 2205) and High-Strength Low-Alloy steel (HSLA X52). A three-factor Response Surface Methodology (RSM) was employed to evaluate the synergistic effects of friction pressure, rotational speed, and friction time. Statistical analysis identified rotational speed as the most significant factor influencing ultimate tensile strength (UTS). The optimized joint, achieved at 2000&#xa0;rpm, 100&#xa0;MPa, and 4&#xa0;s, exhibited a peak UTS of 622.2&#xa0;MPa, matching the base metal strength. Microstructural characterization via SEM and EDS revealed a highly refined Contact Zone (CZ) resulting from dynamic recrystallization, alongside a narrow inter-diffusion layer of Cr, Ni, and Mo that facilitated robust metallurgical bonding. Conversely, deficient joints (3000&#xa0;rpm, 50&#xa0;MPa) failed at the interface via a quasi-cleavage mode, attributed to interfacial 'lack of fusion' and thermal softening in the HSLA heat-affected zone. These results provide a predictive framework for optimizing RFW parameters in oil and gas pipeline applications where DSS–HSLA dissimilar connections are critical.</p>

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Impact of friction welding parameters on the mechanical and microstructural properties of DSS 2205/HSLA X52 dissimilar joints using response surface methodology

  • 期刊论文

  • 发表日期：

    2026年7月25日

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  • Belkacem Tahir,
  • Helal Yazid,
  • Naima Ouali,
  • Seif El Islam Lebouachera,
  • Brahim Belkessa,
  • Ammar Jabbar Hassan,
  • Bouzid Maamache,
  • Billel Cheniti

摘要

This study investigates the influence of continuous drive rotary friction welding (CDFW) parameters on the metallurgical and mechanical integrity of dissimilar joints between Duplex Stainless Steel (DSS 2205) and High-Strength Low-Alloy steel (HSLA X52). A three-factor Response Surface Methodology (RSM) was employed to evaluate the synergistic effects of friction pressure, rotational speed, and friction time. Statistical analysis identified rotational speed as the most significant factor influencing ultimate tensile strength (UTS). The optimized joint, achieved at 2000 rpm, 100 MPa, and 4 s, exhibited a peak UTS of 622.2 MPa, matching the base metal strength. Microstructural characterization via SEM and EDS revealed a highly refined Contact Zone (CZ) resulting from dynamic recrystallization, alongside a narrow inter-diffusion layer of Cr, Ni, and Mo that facilitated robust metallurgical bonding. Conversely, deficient joints (3000 rpm, 50 MPa) failed at the interface via a quasi-cleavage mode, attributed to interfacial 'lack of fusion' and thermal softening in the HSLA heat-affected zone. These results provide a predictive framework for optimizing RFW parameters in oil and gas pipeline applications where DSS–HSLA dissimilar connections are critical.