journal article·2026-07Open access

Microstructural evolution, interfacial phase formation, and mechanical characteristics of dissimilar CP-Ti/stainless steel friction-welded joints

A. Santhakumari, G. Mahadevan, T. Senthilkumar, N. Ramasamy

Abstract

Dissimilar welding between commercially pure titanium (CP–Ti) and stainless steels has gained significant attention in aerospace, marine, and biomedical industries due to combined advantages of high strength, corrosion resistance, and light weight characteristics. However, the influence of various stainless steel (SS) grades on interfacial evolution and the resulting mechanical performance of dissimilar joints with CP-Ti/SS under comparable welding conditions have not been systematically reported. Hence, the present research intends to evaluate the correlation between stainless-steel alloy composition and the evolution of interfacial microstructure, elemental diffusion, hardness distribution, and mechanical performance in friction-welded CP-Ti/stainless-steel joints. Dissimilar joints of CP-Ti with SS304, SS316, and SS321 were fabricated using continuous drive rotary friction welding under optimized welding conditions. The mechanical properties and interfacial microstructure were evaluated using tensile, microhardness, optical microscopy, XRD, and SEM/EDX analysis. The experimental results were reported that the CP-Ti/SS316 exhibited the highest ultimate tensile strength of 507 MPa and the joint efficiency of CP-Ti/SS316 dissimilar joints was increased by 55% and 17.8%, when compared to SS304 and SS321, respectively. Meanwhile, the micro hardness of SS321 dissimilar joints increased by 9.1% and 10.7% at the SS interface as compared to SS304 and SS316, respectively. Microstructural examinations show that SS321's smoother transition zone, and enhanced Ti stability enhances compatibility with CP-Ti while reducing excessive brittle phase formation. Moreover, the results were demonstrated that the variations in stainless-steel alloy composition influenced elemental diffusion, interfacial microstructural evolution, hardness distribution, and consequently the mechanical performance of the friction-welded joints.
Source: openalex_inverted_index · Quality: baseline

Research context

OpenAlex topics: Advanced Welding Techniques Analysis · Shape Memory Alloy Transformations · Intermetallics and Advanced Alloy Properties

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (61)

Show source-provided references
1. Biomedical applications of titanium alloys: a comprehensive review10.3390/ma17010114 ↗
2. On the characteristics of titanium alloys for the aircraft applications10.1016/j.matpr.2017.07.249 ↗
3. Characterization and testing of functionally graded material (SS 347-SS 316L) fabricated through wire arc additive manufacturing10.1007/s11665-025-12468-9 ↗
4. McGuire · 2008
5. Joining of titanium and stainless steel by using different welding processes: a review10.1016/j.matpr.2022.05.590 ↗
6. Dissimilar high-strength steels: fusion welded joints, mismatches, and challenges
7. Lap joining of TC4 titanium alloy to 304 stainless steel with fillet weld by GTAW using copper-based filler wire10.1016/j.jmatprotec.2018.02.020 ↗
8. Metallurgical strategies for the joining of titanium alloys with steels10.1002/adem.201700764 ↗
9. Temperature distribution and residual stress evolution at the interface of CuCrZr/316 L multi-material by laser powder bed fusion10.1016/j.optlastec.2023.109355 ↗
10. Evaluation of welded joints of dissimilar titanium alloy Ti-5Al-2.5 Sn and stainless-steel 304 at different multi-interlayer modes10.1088/2053-1591/ac9600 ↗
11. A review of dissimilar welding for titanium alloys with light alloys10.1051/metal/2021011 ↗
12. Factors influencing Al-Cu weld properties by intermetallic compound formation10.1186/s40712-015-0037-8 ↗
13. Assessment of friction stir spot welding of AA5052 joints via machine learning10.1007/s00707-023-03841-7 ↗
14. Study of plastic flow on intermetallic compounds formation in friction welding of aluminum alloy to stainless steel10.1016/j.jmapro.2021.01.019 ↗
15. Enhancing interfacial bonding and performance in Al/steel inertia friction welding via a Ni interlayer-induced mutual deformation
16. Prediction of properties of friction stir spot welded joints of AA7075-T651/Ti-6Al-4V alloy using machine learning algorithms10.1007/s43452-022-00411-x ↗
17. Recent developments in tensile properties of friction welding of carbon fiber-reinforced composite: a review10.1515/ntrev-2022-0083 ↗
18. The experimental study of CFRP interlayer of dissimilar joint AA7075-T651/Ti-6Al-4V alloys by friction stir spot welding on mechanical and microstructural properties10.1515/ntrev-2021-0032 ↗
19. Investigations on the mechanical properties and microstructure of dissimilar cp-titanium and AISI 316L austenitic stainless steel continuous friction welds10.1016/j.matdes.2010.12.057 ↗
20. Investigation of heat-affected zones of thermite rail weldings
21. Microstructure at friction stir lap joint interface of pure titanium and steel10.1016/j.matlet.2010.07.049 ↗
22. Microstructures and mechanical properties of friction stir welded lap joints of commercially pure titanium and 304 stainless steel10.1016/j.jallcom.2015.01.004 ↗
23. Characterisation of intermetallic phases in fusion welded commercially pure titanium and stainless steel 30410.3390/met8110863 ↗
24. Microstructural analysis and mechanical behavior of SS 304 and titanium joint from friction stir butt welding10.1016/j.msea.2020.139658 ↗
25. Development of large-size dissimilar stainless steel/α-Ti alloy joints by diffusion bonding using vacuum hot press: interface microstructure and tensile response in the temperature range of 77–773 K10.1016/j.msea.2024.146897 ↗
26. Effect of friction time on mechanical and metallurgical properties of continuous drive friction welded Ti6Al4V/SUS321 joints10.1016/j.matdes.2013.11.065 ↗
27. Solid-state diffusion bonding of pseudo-α-Ti alloy to Ti-stabilized stainless steel: with and without interlayer10.1007/s11665-022-06758-9 ↗
28. Mechanical properties of laser welded SS316 and SS32110.35940/ijeat.B3715.089620 ↗
29. Friction stir spot welding of AA5052 with additional carbon fiber-reinforced polymer composite interlayer10.1515/ntrev-2021-0017 ↗
30. Recent developments in ultrasonic welding of similar and dissimilar joints of carbon fiber reinforcement thermoplastics with and without interlayer: a state-of-the-art review
31. Welding microstructure and tensile properties of s45c carbon steel10.18494/SAM.2018.1826 ↗
32. Cooperative deformation mechanism and its role on defect elimination in pressure-controlled Joule-heat forge welding of Ti-6Al-4V/SUS316L dissimilar metals10.1016/j.jmrt.2026.03.110 ↗
33. Diffusion welding of Ti6Al4V and 17-4 stainless steel using Cu/Ni microlayers10.1007/s11665-022-07101-y ↗
34. Evolution of interfacial microstructure and embrittlement mechanism in explosive-welded Al/Steel anode guide rod joints after high-temperature service10.1016/j.jmrt.2026.04.183 ↗
35. Grain boundary diffusion in compositionally complex alloys: a comprehensive review10.1177/09506608251390882 ↗
36. Microstructural characterization and mechanical properties of friction-welded IN718 and SS410 dissimilar joint10.1007/s13632-018-0447-0 ↗
37. Automatic image analysis of surface defects in hybrid welding of dissimilar joints for lifecycle enhancement10.1016/j.mtcomm.2026.115244 ↗
38. A critical review of laser welding of steel with titanium alloys for biomedical applications: challenges, developments, and properties10.1080/09500839.2025.2537089 ↗
39. Formation of intermetallic phases in diffusion-welded joints of aluminium and magnesium alloys10.1007/s10853-010-4841-5 ↗
40. Multielement diffusion and interfacial reaction mechanisms in titanium alloy/precipitation-hardened stainless steel diffusion joints under thermomechanical coupling10.1016/j.matchar.2026.116369 ↗
41. Microstructural evolution and mechanical properties of the dissimilar weld of haynes 282 and AISI 321 using electron beam welding10.1007/s11663-025-03705-6 ↗
42. Inhomogeneous interface structure and mechanical properties of rotary friction welded TC4 titanium alloy/316L stainless steel joints10.1016/j.jmapro.2018.05.001 ↗
43. Theoretical and experimental studies of the structural, phase stability and elastic properties of AlCrTiFeNi multi-principle element alloy10.3390/ma13194353 ↗
44. Enhancement of interfacial structure and mechanical properties of Zr-3 alloy and 304L stainless steel diffusion bonded joint via Ti interlayer introduction10.1016/j.vacuum.2026.115129 ↗
45. Understanding interfacial reactions in Ti–Ni diffusion couple10.3390/ma16062267 ↗
46. Diffusion bonding of commercially pure titanium and 17-4 precipitation hardening stainless steel10.1016/j.msea.2005.10.047 ↗
47. Formation and influencing mechanism of the intermetallic compound in the friction stir welding of immiscible AZ31 and SPHC steel using aluminium powder as an additive10.1016/j.jmrt.2024.05.249 ↗
48. Al2O3/Ti6Al4V diffusion bonding joints using Ag–Cu interlayer10.1016/j.matchar.2009.05.007 ↗
49. Etching strategy for photocatalysis: the evolution of structures and properties10.1002/solr.202300408 ↗
50. Effect of retained austenite on ductility and toughness of a low alloyed multi-phase steel
51. Formation of ultrafine grain and mechanical properties in commercial pure titanium subjected to heavy-reduction thermomechanical processing around β transus temperature10.1016/j.msea.2023.145032 ↗
52. Comprehensive understanding of the mechanical properties and microstructure evolution of aluminum alloy/steel laminates during friction stir-assisted incremental forming with synchronous bonding process10.1016/j.msea.2022.142961 ↗
53. Interfacial microstructural evolution and mechanical properties of Al/steel/Al composite sheets prepared by“ cold spraying+ hot pressing+ hot rolling”10.1016/j.jmrt.2025.08.104 ↗
54. On the influence of surface hardening treatments on microstructure evolution and residual stress in microalloyed medium carbon steel10.1007/s11665-020-04866-y ↗
55. Interface and microstructural characteristics of titanium and 304 stainless steel dissimilar joints by upset butt welding using a gleeble thermo mechanical simulator10.1016/j.jmrt.2023.09.098 ↗
56. Diffusion bonding of microduplex stainless steel and Ti alloy with and without interlayer: interface microstructure and strength properties10.1007/s11661-013-1977-3 ↗
57. Effect of intermetallic compound layer thickness on the interface deformation mechanism and mechanical properties of polycrystalline Cu/Al2Cu/Al layered composite materials10.1016/j.mtcomm.2025.114297 ↗
58. Hybrid additive manufactured tool steels: microstructural modifications and mechanical enhancements through heat treatments10.1016/j.mtla.2025.102552 ↗
59. Dissimilar lap joining of 304 stainless steel to CP-Ti employing friction stir welding10.1016/j.matdes.2010.12.026 ↗
60. Microstructural and mechanical behaviour of friction welded SS316L components fabricated by selective laser melting
61. Effect of interfacial microstructure evolution on mechanical properties and fracture behavior of friction stir-welded Al-Cu joints10.1007/s11661-015-2909-1 ↗