Friction taper stitch welding (FTSW) is a novel technique that uses multiple inserts to conceal surface crack in a given substrate. The inserts are rotated and forced to fill the crack as plasticized material, and forge with the substrate in solid-state. The process is well suited for alloys such as duplex stainless steel, which suffers degradation of properties during fusion welding. A detailed experimental and theoretical investigation is presented here on FTSW of a duplex stainless steel (DSS). The experimental results show the presence of a ferrite-rich phase along the interface. The results computed by the numerical process model reveal a direct influence of thermal cycle in the amount of ferrite along the joint interface. The welded joint shows near homogeneous structure and properties similar to those of the substrate.
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