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In this study, metallurgical properties of AISI 1040 steel and high-chromium white cast iron joined using friction welding process was investigated experimentally. Scanning electron microscopy, optical microscopy, energy-dispersive spectrometry, electron backscattered diffraction, X-ray diffraction and elemental mapping analysis were used to analyze the microstructures of the weld interfaces. The joint strength was evaluated with tensile testing and microhardness, and the fracture behavior was examined by SEM. HCrWCI and AISI 1040 steel were successfully welded using the FW. Increasing rotational speed was an effective parameter on the joint quality. The diffusion of Cr, C, Mn, Mo, Si and Ni elements occurred more in high-speed joints. The increase in plastic deformation caused the formation of fine grains and increased strength. [ABSTRACT FROM AUTHOR]

Electro-spark deposition (ESD) or low energy welding (LEW) technique allows the coating of metallic materials with different metal and alloys, conductive ceramics and conductive ceramic metal composites. It is also known as micro-joining process to improve the wear properties of the substrate or to obtain a more durable upper superficial coating. In this study, the surfaces of AISI 1040, AISI 4140 and AISI 5140 steels were coated with WC electrode at constant rotational speed and then characterized by a metallographic study. A homogeneous coating thickness was observed in microscopy studies and the formation of W2C phase in the coating layer was determined in XRD analysis. Hardness of WC coated samples increased approximately 5 times. Abrasion tests were carried out by ball-on disc method with WC–Co ball at 250 m under 5N load. In the abrasion tests with WC–Co ball, the best abrasion resistance is obtained with WC coated AISI 5140 steel, while the lowest strength is obtained with uncoated AISI 4140 steel. [ABSTRACT FROM AUTHOR]