Improved Microstructure Evolution and Corrosion Resistance in Friction-Welded Dissimilar AISI 1010/D3 Steel Joints Through Post-Weld Heat Treatment

To achieve the desired material properties of automotive components made by friction welding, post-weld heat treatment is critical. The high temperatures encountered during the friction welding of steels can lead to changes in the microstructure, especially in the heat-affected zones. In the present work, a D3 tool steel and an AISI1010 structural steel are friction welded by varying the rotational speed, and this is followed by post-weld heat treatment. Microstructural evaluation was performed on the friction-welded joints and those produced after heat treatment. Micrographs taken by scanning electron microscope show the formation of distinct zones with ultrafine grains at the interface. Zone measurements at the interfaces of the joints provide information on the proportions of the various zones formed during friction welding. Depending on the rotation speed, the width of the heat-affected zone (HAZ) can range from 10.8 to 19.5 mm, and the width of the total deformed zone varies from 700 to 1070 µm. The width of the fully plasticized zone is between 48 and 380 microns. The region of the friction-welded joint at 1600 rpm shows fine ferrite grains with a width of 48 µm FPDZ, which increase the strength of the joint according to the Hall–Petch equation. Primary carbides are dissolved in the ferrite matrix, and secondary carbides are formed due to the effects of alloying elements such as chromium in particular. Although the formation of secondary carbides cannot be prevented, at higher speeds the primary carbides are dissolved and the tendency to form secondary carbides is reduced. Post-weld heat treatment helps to redistribute these phases and leads to a more homogeneous material structure. The results show that post-weld heat treatment greatly improved the corrosion resistance of dissimilar AISI 1010/D3 steel joints produced by means of friction welding. Coarse grains have been eliminated, and thus the galvanic corrosion at the weld interface is alleviated and reduced. Post-weld heat treatment reduces the corrosion rate and weight loss significantly, by 54.8% and 60%.