Finite Element Simulation and Experimental Analysis of the Thermo-Mechanical Properties of Dissimilar S275 and 316L Austenite Stainless Steels using the RFW Process

Abstract

This research examines the effect of thermomechanical and microstructural constituents on welding of AISI 316L (austenite stainless steel) and S275 steel. A Finite Element Model (FEM) was constructed using ANSYS 19.1, and an experimental study was conducted using the Rotary Friction Welding (RFW) process. It was determined that there is a genuine correlation between the simulation FEM and the experimental procedure with regard to the thermal profile and ultimate yield strength, particularly when a welding speed of 2,000 rev/min is employed. At that speed, the higher temperature recorded and calculated was 1,450 oC. The discrepancy between the numerical FEM and the experimental temperature profile for the peak temperature calculation was determined to be 2.78%. The mechanical analysis was conducted through tensile force calculations and experiments, the results of which indicated an estimated error of 12%. The calculated error for the ultimate yield strength of the various samples is less than 6% for tensile strength. Upon tensile testing, failure occurred in the S275 sample. The microstructure exhibited increases in Cr and Ni of 1.2% and 1.01%, respectively, in comparison to the base metal of 316L stainless steel.