Solid state crack repair by friction stir processing in 304L stainless steel

Abstract Friction stir processing (FSP) was investigated as a method of repairing cracks in 12 mm thick 304L stainless steel plate. Healing feasibility was demonstrated by processing a tapered crack using a PCBN/W-Re tool with a 25 mm diameter shoulder and a pin length of 6.4 mm. The experiment showed that it was possible to heal a crack that begins narrow and then progressively grows up to a width of 2 mm. Bead on plate experiments were used to find the best parameters for creating a consolidated stir zone with the least amount of hardness difference compared to the base metal. Grain refinement in some specimens resulted in much higher stir zone hardness, compared to base metal. A plot of grain size versus microhardness showed a very strong inverse correlation between grain size and hardness, as expected from the Hall-Petch relationship. Corrosion testing was carried out in order to evaluate the effect of FSP on potential sensitization of the stir zone. After 1000 h of intermittent immersion in 3.5% saline solution at room temperature it was found that no corrosion products formed on the base material controls or on any of the friction stir processed specimens.