Effect of post-weld heat treatment on microstructure and mechanical properties of rotary inertia friction welded dissimilar 422-4140 martensitic steel piston joints

Wang, Yiyu; Sebeck, Katherine; Gingrich, Eric; Tess, Michael; Haynes, James A.; Muralidharan, Govindarajan; Will, Kurt; Pierce, Dean T.

doi:10.1016/j.jmrt.2025.11.108

Effect of post-weld heat treatment on microstructure and mechanical properties of rotary inertia friction welded dissimilar 422-4140 martensitic steel piston joints

Journal Article · Tue Nov 11 19:00:00 EST 2025 · Journal of Materials Research and Technology

DOI:https://doi.org/10.1016/j.jmrt.2025.11.108· OSTI ID:3009437

^[1]; Sebeck, Katherine ^[2]; Gingrich, Eric ^[2]; Tess, Michael ^[2]; ^[1]; ^[1]; Will, Kurt ^[3]; ^[1]

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
US Army Combat Capabilities Development Command Ground Vehicle Systems Center, Warren, MI (United States)
Tenneco Powertrain, Plymouth, MI (United States)

The study investigated how post‐weld heat treatment (PWHT) temperature affects the microstructure and localized deformation/fracture during bend testing of rotary inertia friction welds (RIFW) between AISI 422 stainless steel and AISI 4140 steel. RIFW produced a fully martensitic interface with approximately 550 HV hardness in both the thermo-mechanically affected (TMAZ) and heat‐affected zones (HAZ). Due to differences in temper resistance, the 4140 TMAZ/HAZ softened progressively under PWHT temperatures from 525 °C to 700 °C, while the 422 TMAZ unexpectedly maintained about 550 HV up to 600 °C before significantly softening at temperatures ≥625 °C. This asymmetric softening generated steep hardness gradients across the interface at temperatures ≤600 °C. Furthermore, carbon migration across the interface was minimal up to 600 °C, moderate at 625 °C, and by 700 °C produced a carbide‐rich eutectoid layer in the 422 TMAZ alongside a carbon‐depleted soft ferrite layer in the 4140 TMAZ. Strain during bending was PWHT‐dependent, concentrating on the 4140 side; in as-welded joints, the high hardness led to deformation and crack initiation in the base metals, whereas in PWHT samples, cracking initiated in the softened 4140 TMAZ near the interface. The intermediate PWHT temperature of 625 °C offered the best balance of limited carbon diffusion across the interface, relatively low peak weld hardness and minimized hardness gradients across the interface, more homogenous deformation, and good bend test performance.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Vehicle Technologies Office (VTO)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 3009437

Journal Information:: Journal of Materials Research and Technology, Journal Name: Journal of Materials Research and Technology Vol. 39; ISSN 2238-7854

Publisher:: Elsevier - Brazilian Metallurgical, Materials and Mining AssociationCopyright Statement

Country of Publication:: United States

Language:: English

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