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Comparative Study of Hybrid Friction Welding on Medium Carbon Steel

Suresh Kumar F. Parmar, Ravi Dave

Abstract


This study presents a comparative investigation of conventional friction welding (FW) and hybrid friction welding (HFW), where friction welding is combined with Gas Tungsten Arc Welding (GTAW), on medium carbon steel EN08/080M40 having 10 mm diameter. A modified conventional lathe machine equipped with specialized fixtures for pressure measurement and torch positioning was used to perform experiments under varying rotational speeds (800–1200 rpm) and forge pressures (10–14 kg/cm²). Results show that HFW reduced welding time by up to 85% compared to FW while maintaining comparable mechanical properties. HFW exhibited higher yield strength, particularly at lower spindle speeds, whereas FW demonstrated superior tensile strength at higher speeds. Hardness testing revealed higher values in FW joints due to finer grain structures, while metallographic analysis confirmed that HFW joints displayed coarser grains with reduced pearlite content. Overall, HFW provides significant advantages in productivity with acceptable mechanical performance, making it a cost-effective alternative for industrial applications.


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