Microstructure and mechanical properties of dissimilar friction stir welded type 304 austenitic stainless steel to Q235 low carbon steel

In this work, friction stir welding (FSW) was used to weld dissimilar metals (Type 304 stainless steel (SS304) and Q235 low carbon steel). The microstructure, interfacial characteristics, residual stress distribution and mechanical properties of the joint were investigated. The results show that FSW results in grain refinement in the stir zone (SZ) and thermal-mechanical affected zone (TMAZ) in SS304 side. Discontinuous dynamic re crystallization and twinning-induced dynamic recrystallization are the main grain refinement mechanisms. Dynamic recovery occurs in the heat-affected zone (HAZ). On the Q235 steel side, the acicular ferrite and pearlite are generated in the SZ, which is due to its peak temperature of up to Ac-3. Additionally, the amount of acicular ferrite decreases in the TMAZ. Continuous and discontinuous dynamic recrystallization is the main recrystallization mechanism in the two regions. The interfacial bonding mechanism of FSW joint consists of both mechanical and metallurgical bonding. In addition, the difference in expansion coefficient and microstructure between the two steels results in the formation of residual compressive stress in the SZ. Grain refinement and acicular ferrite are responsible for the microhardness distribution in the whole joint. The tensile strength of FSW joint is 493 MPa, which is more than that of Q235 steel by around 4%. However, the elongation is 17%, which shows a decrease of around 50%. Furthermore, the fracture surface shows ductile fracture with dimples.