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Friction Stir Welding of Carbon to Stainless Steel

Friction Stir Welding of Carbon to Stainless Steel

Friction Stir Welding of Carbon to Stainless Steel

(OP)
I am looking to make a weld joint (ASME IX) between carbon steel and SS304L thick walled pipe, approx. 0.25" ID and 0.62" OD. Arc welding between these two is proving difficult because of the mandated filler metal (I know, it should be easy).
The configuration seems amenable to FSW. Does anyone (with actual knowledge or experience) have any suggestions or advice? Are there metallurgical or bonding difficulties inherent with the FSW process for this combination of materials?
Thanks in advance.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

RE: Friction Stir Welding of Carbon to Stainless Steel

FSW gets more difficult as the melting point of the materials goes up, hence why it is common in Al.
What filler and welding method are you trying?

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P.E. Metallurgy, Plymouth Tube

RE: Friction Stir Welding of Carbon to Stainless Steel

(OP)
52M...designed to fail. Which is why I am exploring FSW.
All results from my googling talk about using a spinning tool between two plates; I am interested in rotating two bars/pipes on a lathe arrangement, pushing them together without a tool. I would be surprised if that hasn't been accomplished already, between like metals at least.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

RE: Friction Stir Welding of Carbon to Stainless Steel

Oh, simple friction welding.
It can be done but you will need to machine the flash out of the ID afterwards.
There are many commercial providers.
I used to weld stubs of 625 onto 4130 shafts this way.

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P.E. Metallurgy, Plymouth Tube

RE: Friction Stir Welding of Carbon to Stainless Steel

Not sure if it will help, but you can also use the search terms "inertia welding" or "continuous friction welding". These are the two different processes of the friction welding you're looking for.

RE: Friction Stir Welding of Carbon to Stainless Steel

(OP)
Thanks EdS and Hat,
That clarified things for me, and I found lots of links.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

RE: Friction Stir Welding of Carbon to Stainless Steel

Just be warned, the flash will fill the ID at the joint and need to be gun drilled out.
Fortunately it will mostly be the steel.
If someone says that they can minimize this then they aren't displacing enough metal to generate a good joint.

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P.E. Metallurgy, Plymouth Tube

RE: Friction Stir Welding of Carbon to Stainless Steel

(OP)
I am aware of the flash issue. This job might be better accomplished by starting with solid bars.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

RE: Friction Stir Welding of Carbon to Stainless Steel

or, if one piece needs to be longer than the other make it hollow.
Then you are drilling out the weld and shorter piece.

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P.E. Metallurgy, Plymouth Tube

RE: Friction Stir Welding of Carbon to Stainless Steel

(OP)
EdS,
Do you mean one solid and one hollow?

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

RE: Friction Stir Welding of Carbon to Stainless Steel

(OP)
Axle welding.

The trimming seen at 0:42 is a nice touch!

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

RE: Friction Stir Welding of Carbon to Stainless Steel

Yes, I mean one piece solid (the short one) and the longer piece hollow (hopefully the SS).
This might help simplify things.
We ended up not using a square-flush joint. We had a slight taper on one piece and a step in the solid one to assist centering.

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P.E. Metallurgy, Plymouth Tube

RE: Friction Stir Welding of Carbon to Stainless Steel

(OP)
Lots of folks are doing this in aerospace and automotive, but what about ASME pressure equipment? The process is included in Section IX.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

RE: Friction Stir Welding of Carbon to Stainless Steel

A company I worked for years ago used friction welding to attach hollow threaded ends to drill pipe.

Ted

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