International Journal of Engineering Bussines

and Social Science

Vol. 1 No. 03, January-February 2023, pages: 179-191

e-ISSN: 2980-4108, p-ISSN: 2980-4272

https://ijebss.ph/index.php/ijebss

179

The Strength Material Welding Dissimilar of Method GTAW AISI

1045 With HSS for Application Milling Tool

Toto Triantoro.B.W

, P.Y.M Wibowo Ndaruhadi

1,2

Mechanical Engineering Dept, Universitas Jenderal Achmad Yani Bandung, Indonesia

E-Mail:

trians65@yahoo.co.id;

wibowo.ndaruhadi@lecture.unjani.ac.id

Submitted:05-02-2023, Revised: 09-02-2023 , Publication: 20-02-2023

Keywords

Abstract

Welding Dissimilar;

GTAW AISI 1045; HSS;

Mechanical Properties

Dissimilar welding is a permanent joining of two dissimilar materials as the

application of this welding is used in milling tools that receive a large load when

used. There is certainly that there is a change in the microstructure between the

HAZ (Heat Affective Zone) regions, and this causes a decrease in the strength of

the material, because residual stresses, defects, and cracks due to dissimilar

welding will become a problem in itself. This study will connect two different

materials between AISI (American Iron and Steel Institute) 1045 and HSS (High-

Speed Steel), using the GTAW (Gas Tungsten Arc Welding) welding method.

Welding results from tensile strength, hardness, and microstructure inspection as

well as calculating grain size in the weld metal, HAZ, and base metal areas are the

focus of the analysis. This dissimilar welding will compare three welding amperes

that are ±110A, ±167A, and ±225A. This amperage is used based on the welding

results that have been carried out for both materials with the AWS (American

Welding Society) standard for circular welding of solid round materials such as the

shape of a milling tool. GTAW welding method is very good and strong, but the

hardness of the weld metal is large and will cause brittleness. The difference in

hardness between weld metal and HAZ is significant due to the rapid heat input

failing in the area between weld metal and HAZ. Tensile test results for amperage

±110A tensile strength 84.70 kgf/mm2, the hardness is 665.58 HV in the HAZ area

of HSS material. Examination of the microstructure in this area has austenite,

martensite, and carbide phases, it looks less than ±167A of amperage welding, the

results of the hardness test are 774.70 HV in the HAZ area of HSS material so this

area will be more brittle. The smaller the grain size, the higher the hardness. The

Selection of dissimilar welding filler metal produces good joint strength. While the

amperage welding of ±225A broke on welded metal with a tensile strength of

43.41 kgf/mm2, the hardness in the HAZ area was made of HSS with a hardness of

772.37 HV. The smallest hardness value is in the base metal area of AISI 1045

material with a hardness of 264.45 HV. The difference in hardness is much

different between HSS and AISI 1045, indicating the use of filler metal with poor

connection strength for large amperes.

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1. Introduction

The development of welding technology to obtain the strength of welding joints. In dissimilar welding as a

milling tool splicing application. Welding with low cost is needed in the world of the medium manufacturing

industry. The sluggish manufacturing industry due to the outbreak of the COVID-19 virus has prompted researchers

to conduct studies, especially regarding dissimilar welding technology. Welding is part of the manufacturing industry

in developing countries such as Indonesia; this will increase the income of the middle to lower industrial sector

(Groover, 2006). Strong construction makes welding one of the choices in industrial engineering construction. The

quality of the welding results can not only be seen visually but must be known in a structured manner with various

forms of application [10] (Perdana et al., 2019).

The most popular welding uses an electric arc, including the GTAW method. This welding is for lightweight

construction, so it can withstand high strength, is easy to implement, and is quite economical. The main weakness is

the occurrence of changes in the microstructure of the welded material, especially for dissimilar welding, so that it is

possible to change the physical and mechanical properties of the welded material(Wardoyo et al., 2014).

Determining the welding parameters in the dissimilar welding process is a separate obstacle in this study. In addition

to these weaknesses, the results of dissimilar welding, among others, will occur a large voltage spike from one of the

materials which is an obstacle when determining the welding amperage that is not precise. Inappropriate selection of

parameters will cause changes in the microstructure including the welding area and the HAZ area so that there will

be a decrease in the strength of the material in that area, residual stresses, and defects will appear, cracks will occur

due to the welding (Weman, 2011).

Based on the background above, this research can formulate several problems that will be raised as the

formulation of the problem:

1. To obtain dissimilar welding amperage, as the strength of the connection resulting from the GTAW method of

welding on two different materials for application in milling tools.

2. Analyzing the results of dissimilar welding between AISI 1045 material and HSS material, in circular welding

of solid round materials as milling tool applications including: tensile strength, hardness and microstructure

inspection as well as calculating grain size in the weld metal, HAZ and base metal areas.

To get the optimal welding amperage based on the AWS A5-12M welding standard in dissimilar welding,

joining different materials with the GTAW welding method, as an application for tool milling in further research

(Arc, n.d.). Obtaining dissimilar welding amperage with the GTAW method based on the AWS standard between

AISI 1045 steel and HSS material by varying the welding ampere, namely, ±110A, ±167A, and ±225A, this welding

amperage data is the best ampere from previous research(Wiryosumarto & Okumura, 2000). It is expected to be a

reference and input for the dissimilar welding process with AWS standards with low and economical operational

costs in terms of operations and processes for middle and lower manufacturing industry players related to the

welding process, solid round shape, application to tool milling equipment or other applications(Black & Kohser,

2017).

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Figure 1. Research flow chart

2. Research Method

The research method was carried out, with experimental and absorption methods, materials, and equipment

were prepared. Then it is analyzed as shown in Figure 1, the planned research flow diagram to facilitate the stages of

the research process.

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Figure 2. Design sample tensile test

Tensile testing is a mechanical test that aims to determine the strength of a metal, including; tensile strength,

yield strength, and strain. Before welding, the workpiece is turned and made a seam angle, using a lathe according to

the ASTM (American Test and Material Association) A-370 tensile testing standard size, with a single V seam shape

on each test sample as shown in Figure 2 above (Zukauskaite et al., 2013).

3. Results and Discussions

The first step is the process of making tensile samples referring to the ASTM E-370 standard, using a universal

lathe on both types of materials, namely, AISI 1045 material and HSS material. Followed by the process of making a

welding seam, namely a single V seam with an angle of 60°

Figure 3. Tansile test sample production.

Welding Process.

In the GTAW method welding process for AISI 1045 medium carbon steel and HSS with a workpiece

diameter of 20 mm and a length of 220 mm, all amperes are varied in two stages, the first stage is rooting, the second

stage is filler

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Figure 4. Welding dissimilar method GTAW at each

welding ampere condition.

Table 1: Result welding GTAW with ampere ±110A

Figure 5 Result welding dissimilar ampere ±110A

Tabel 2: Result welding GTAW with ampere ±167A

Figure 6. Result welding dissimilar ampere ±167A

Table 3: Result welding GTAW with ampere ±225A

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Figure 7. Result welding dissimilar ampere ±225A

The next stage after the welding process is complete is to clean the capping contained in the results of the

welding process. The cleaning of the welding capping is carried out utilizing a lathe process using a carbide lathe.

Figure 8 below is a picture of the capping cleaning process that occurs from the results after the dissimilar welding

process.

Figure 8. Result process remove capping

Heat Input Calculation.

The welding heat input comes from the electric arc using the following equation:

Welding specimens with an ampere of ±110A of welding heat input were obtained at 487.38 Kj/mm. While the

amperage welding specimen is ±167A, the welding heat input is 498.92 Kj/mm. Welding specimens with amperage

of ±225 welding heat input of 682.10 Kj/mm. So the greater the welding amperage, the greater the heat input.

Non- Destructive Inspection.

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Using the dy-penetrant (NDT) method it will provide visual information on the occurrence of cracks. This can

be obtained by using a tool in the form of a liquid that has a specific color, including: red or a color that will move

under ultra violet light. Of course the cracks are thin enough that they can't be seen with the naked eye. After all the

samples were cleaned using MD125 thinner, the dy-penetrant was sprayed. The next step, the sample is cleaned

again with MD125 thinner liquid followed by spraying developer liquid.

Figure 9. Result process liquid spray dy-penetrant.

Thus, the liquid part of the developer will coat the area above the crack and change color. If the liquid

penetrant used is red, the defects or cracks will appear and turn red.

Figure 10. Result process liquid spray developer

The results of the dy-penetrant inspection for ±110Ampere amperage showed that one sample was cracked.

As for the amperage of ±167 amperes, the dy-penetrant fluid appeared in all the crack samples clearly visible. For an

amperage of ±225Amper, one sample looks cracked.

Tensile Test.

Tensile testing is carried out using the ASTM A-370 standard. By using the Instron brand tensile testing

machine with a maximum capacity of 20 tons, with an engine movement rate of 1.3 – 2.5 mm/minute at a test

temperature of around 26°C. Sample testing was carried out with three samples each with varying conditions of

welding amperage in this study.

Table 4: Result tensile strength variation ampere

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Figure 11. Result tensile strength for ampere ±110A

Figure 12. Result tensile strength for ampere ±167A

Figure 13. Result tensile strength for ampere ±225A

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Figure 14. Graph of tensile strength every ampere

Based on the test results, as in table 4 above for amperes ±110A the tensile strength is 83.94 kgf/mm

and

84.13 kgf/mm

. This indicates that the welding connection with filler metal used and the welding parameters carried

out, one of which is welding amperage, results in good joint strength. For welding amperage ±167A the tensile

strength is 53.20 kgf/mm

and 37.01 kgf/mm

where the welding heat input affects the mechanical properties of the

material itself. For welding amperage ±225A with a tensile strength value of 89.07 kgf/mm

while for S.3 3

specimens, it breaks in the weld metal area with a tensile strength value of 43.41 kgf/mm

Hardness Test.

Hardness testing was carried out using the Vickers method with the ASTM E-92 standard. Data collection

was carried out after tensile testing, hardness testing was carried out at 15 points, namely; three points in the base

metal of AISI 1045 material, three points in the base metal region of HSS material, three points in the heat-affected

area of AISI 1045 and, HSS materials, and three points in the weld metal area.

Figure 15. Hardness testing area position.

Hardness testing was carried out using an Alfa durometer machine with the Vickers method with a load of

300 grams, the type using a diamond pyramid indenter with a pyramid angle of ±136

Figure 16. Average hardness value on ampere ±110A.

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Figure 17. Average hardness value on ampere ±167A.

Figure 18. Average hardness value on ampere ±225A.

From the data, the highest average hardness value is in the weld metal area at welding amperage ±110A

with a hardness value of around 462.62 HV, while in the HAZ area, the hardness value is around 665.58 HV, and in

the base metal area of AISI 1045 the hardness value is around 274.64 HV, and base metal HSS hardness value of

about 309.72 HV. While the average hardness value for welding amperage ± 167A weld metal area 388.49 HV, HAZ

area HSS material 774.7 HV, and HAZ area AISI material 1045 around 288.83 HV.

While the average hardness value for welding amperage ±225A, the weld metal region is 376.38 HV, The

HAZ region HSS material is 772.37 HV, and the HAZ area is AISI material 1045 536.48 HV. Meanwhile, for

welding amperage ±110A, the value of hardness in the weld metal area is 462.62 HV and the hardness value in the

HAZ area of HSS material is 665.58 HV and the hardness value is in the HAZ area of AISI 1045 309.64 HV

material. Where the difference in hardness values between the weld metal area and the two materials in the HAZ area

is quite small compared to the welding amperage of ±167A and ±225A.

Microstructure Inspection.

Examination of the microstructure to determine the structure formed in the three areas of dissimilar welding

between AISI 1045 material and HSS material, namely, weld metal, HAZ and base metal areas (Ritonga &

Purwaningsih, 2018). The preparation stage for microstructure inspection is done by cutting each sample using a

disc-cutting machine, then a grinding process is carried out with an increase in sandpaper roughness from 300 to

4000. Followed by the polishing process using bludru cloth and using paste. Using a certain optical microscope that

has the ability to magnify up to 500x, the microstructure can be examined after loading, namely after tensile testing.

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Figure19.Microstructure of ampere ampere±110 welding result in three weld areas materials AISI 1045 & HSS

In the base metal area of AISI 1045 ampere welding ±110A 500x magnification, the white ferrite phase

fused in pearlite looks dark in the large fused area, in the balance between ferrite and pearlite. In the base metal area

of HSS material, there is an austenite phase, which is a solid solution of free carbon and iron in gamma iron. A small

amount of carbide and martensitic in the HAZ AISI 1045 area is affected by heat with a sharp shape and a little

bainite with a fine sharp shape, is also in the HAZ area of the HSS material. In the weld metal area, the ferrite phase

changes to a nodular graphite phase and a little iron carbide so that in this area it is slightly harder than in the two

base metal regions.

Figure 20.Microstructure of ampere amper ±167 welding result in three weld areas materials AISI 1045 & HSS.

While the welding amperage is ±167A in the base metal area of AISI 1045 material, the pearlite phase is more

visible than the ferrite phase which is getting smaller and smaller. Likewise, in the base metal area, the austenite,

martensite and iron carbide phases of HSS materials are more visible than the amperage of ±110A. The grain shape

also decreases uniformly indicating an increase in hardness.

While the welding amperage of ±167A AISI 1045 material for the HAZ region, the pearlite and ferrite phases

re-assembled were larger but the pearlite phase was more abundant than the ferrite. While the martensite and bainite

phases with higher welding amperage will be more numerous. The bainite phase is formed from ferrite and cementite

which is sharp long soft or in the form of plates arranged depending on the welding amperage.

For the weld metal pearlite area is seen very little and the ferrite phase is absent, martensitic is seen a lot. The

nodular graphite and carbide phases increase with increasing welding amperage and hardness increases.

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Figure 21.Microstructure of ampere amper ±225 welding result in three weld areas materials AISI 1045 & HSS.

At the welding amperage of ±225A, the AISI 1045 material still has ferrite and pearlite turns into cementite.

Meanwhile, in the HSS base metal area, there is a small amount of austenite, martensite, and carbide.

The austenite phase is a solid solution of free carbon (ferrite), and iron (Fe) in gamma. Heating the steel,

after the upper critical temperature, the formation of the finished structure becomes a hard, ductile, and non-magnetic

austenite. This condition is able to dissolve large amounts of carbon, and transfer occurs during the heating and

cooling of the workpiece (Rudiyanto et al., 2022). In the HAZ area, the AISI 1045 ferrite and pearlite, and martensite

materials are much reduced in the form of a smaller structure but, more and more bainite is seen. This phase is

formed from ferrite and cementite is formed with higher amperage, whereas bainite will increase with increasing

temperature.

In the weld metal region, the pearlite and ferrite phases are almost absent. Martensite is almost evenly

distributed, as are the nodular graphite and carbide phases. This is evidenced by the high value of violence in this

area.

Grain Size Calculation.

The formula for calculating grain size using the Heyne method is:

Table 5: Calculation of grain size in each condition

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4. Conclusion

The highest average tensile strength value of the specimen with amperage ±110A is 84.70 kgf/mm2, while

the lowest tensile strength is at amperage ±167A at 40.17 kgf/mm2. From the results of the ampere hardness test

±110A, the highest hardness value of 665.58 HV is found in the HAZ area of the HSS material. For amperes

±167A the highest hardness value is 774.70 HV which is found in the HAZ area of the HSS material. For

amperes ±225A the highest hardness value is 772.37 HV in the HAZ area of HSS material. For this reason, the

HSS material in the HAZ area with the highest hardness value can be said to be very strong and brittle.

The results of the microstructure examination, obtained the Heat Affected Zone area of HSS material with

500x magnification, visible phases of austenite, cementite, martensite and bainet and carbide indicating that this

area has the highest hardness. Likewise in the weld metal area, these phases are dominantly visible. The grain

size calculation is, as a control for the hardness test, the smaller the grain size, the harder the area.

5. References

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Black, J. T., & Kohser, R. A. (2017). DeGarmo’s materials and processes in manufacturing. John Wiley & Sons.

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Perdana, S., Budiarto, U., & Santosa, A. W. B. (2019). Pengaruh Variasi Waktu Penahanan (Holding Time) pada

Perlakuan Panas Normalizing Setelah Pengelasan Submerged Arc Welding (SAW) pada Baja SS400

terhadap Kekuatan Tarik, Tekuk dan Mikrografi. Jurnal Teknik Perkapalan, 8(1), 21–30.

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under the terms and conditions of the Creative Commons Attribution (CC BY SA) license

(https://creativecommons.org/licenses/by-sa/4.0/).