![]() The weldability of these UHSS is, therefore, a critical characteristic that is currently limiting their widespread use. These steels, manufactured using accelerated cooling to achieve the desired microstructures, are generally not resistant to high heat inputs and, as a result, welding by conventional fusion processes can degrade their properties. ![]() New ultra-high-strength steels (UHSS) offer superior mechanical properties enabling leaner, lighter, and, therefore, more cost-efficient structures for a wide range civil, marine, offshore, and other applications. Welding is the main manufacturing technique applied in the production of large and complex steel structures. The yield strength efficiency was about 70%. The impact toughness of the best weld condition overmatched the base material by over 37%, at both − 40 and − 60 ☌. Results show that FSW enables welding HSS within the intercritical temperature domain. ![]() ![]() Microscopic analyses, including optical microscopy and electron backscatter diffraction, were used to evaluate the microstructure. The effect of the different peak temperatures was evaluated by mechanical testing, including bending, tensile testing with digital imaging correlation, Charpy impact test, and hardness measurements. Temperatures were measured using thermocouples positioned at the mid-thickness of the workpiece, at 5 to 10 mm from the joint line. A HSS produced by a thermo-mechanically controlled process was welded by FSW with peak temperatures, measured within the processed zone, ranging from about 900 to 650 ☌. This work evaluates the influence of different FSW peak temperatures and cooling rates on the properties of a modern HSS. ![]() Friction stir welding (FSW) can join HSS at low peak temperatures, better preserving the properties of the base material. The ability to take full advantage of these modern HSS is limited by their weldability. The need for weight reduction without compromising load-bearing capacity has driven the development of modern high-strength steels (HSS). ![]()
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