OPTIMIZATION OF DISSIMILAR STEEL SOLID RODS IN FRICTION WELDING USING THE TAGUCHI METHOD

This project aimed to explore the joining of dissimilar ferrous materials—AISI 304 stainless steel and MS1018 mild steel—through the process of friction welding. Although the initial objective was to integrate induction heating to form a hybrid friction welding setup, limitations in equipment and system functionality led to the execution of the project using conventional rotary friction welding only. Despite this, the results obtained from the experimental trials were conclusive, valuable, and demonstrated the practicality and reliability of solid-state welding for such dissimilar material combinations. A total of twelve weld specimens were prepared and tested using four different rotational speeds (2000, 3000, & 4000 RPM), with each speed followed by a different cooling method (air, water, and oil). The welding process produced visually acceptable joints in all cases, with no surface defects, cracks, or porosity detected during non-destructive inspection. Flash formation was consistent and symmetrical in most samples, particularly in air- and oil-cooled conditions. Tensile strength analysis showed that weld quality and performance improved with increasing rotational speed, with the best results observed at 3000 RPM with oil cooling, achieving a peak UTS of 396 MPa. Most specimens fractured in the mild steel base material rather than the weld zone, indicating sound metallurgical bonding and effective joint strength. The process demonstrated repeatability, controllability, and performance levels suitable for structural and fabrication applications. Overall, the project successfully achieved its technical objectives within the limitations of available resources. The findings confirm that rotary friction welding is a viable and efficient method for joining stainless steel and mild steel components and provide a strong performance baseline for future experimentation involving hybrid configurations.

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