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    Characteristic properties of AlTiN and TiN coated HSS materials
    (Emerald Group Publishing Ltd, 2015) Sahin, Mumin; Misirli, Cenk; Ozkan, Dervis
    Purpose - The purpose of this paper is to examine mechanical and metallurgical properties of AlTiN- and TiN-coates high-speed steel (HSS) materials in detail. Design/methodology/approach - In this study, HSS steel parts have been processed through machining and have been coated with AlTiN and TiN on physical vapour deposition workbench at approximately 6,500 degrees C for 4 hours. Tensile strength, fatigue strength, hardness tests for AlTiN- and TiN-coated HSS samples have been performed; moreover, energy dispersive X-ray spectroscopy and X-ray diffraction analysis and microstructure analysis have been made by scanning electron microscopy. The obtained results have been compared with uncoated HSS components. Findings - It was found that tensile strength of TiAlN- and TiN-coated HSS parts is higher than that of uncoated HSS parts. Highest tensile strength has been obtained from TiN-coated HSS parts. Number of cycles for failure of TiAlN- and TiN-coated HSS parts is higher than that for HSS parts. Particularly TiN-coated HSS parts have the most valuable fatigue results. However, surface roughness of fatigue samples may cause notch effect. For this reason, surface roughness of coated HSS parts is compared with that of uncoated ones. While the average surface roughness (Ra) of the uncoated samples was in the range of 0.40 mu m, that of the AlTiN- and TiN-coated samples was in the range of 0.60 and 0.80 mu m respectively. Research limitations/implications - It would be interesting to search different coatings for cutting tools. It could be the good idea for future work to concentrate on wear properties of tool materials. Practical implications - The detailed mechanical and metallurgical results can be used to assess the AlTiN and TiN coating applications in HSS materials. Originality/value - This paper provides information on mechanical and metallurgical behaviour of AlTiN- and TiN-coated HSS materials and offers practical help for researchers and scientists working in the coating area.
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    Characterization of mechanical properties in AISI 1040 parts welded by friction welding
    (Elsevier Science Inc, 2007) Sahin, Mumin; Akata, H. Erol; Gulmez, Turgut
    This study deals with the importance of welding in manufacturing methods. There are various welding methods that have been developed to obtain suitable joints in various applications. However, friction welding, which is an alternative manufacturing method, is one of the methods that has been widely used for many years. In the present study, an experimental friction welding setup, which is a continuous drive friction welding set-up, was used in the experiments. Firstly, optimum parameters were obtained to join parts having equal diameter: Secondly, the effects of welding parameters on welding strength were investigated. Later, the mechanical properties of joints were examined by using tensile tests, fatigue tests, notch-impact tests and hardness tests. Finally, the results obtained were shown and discussed. (C) 2006 Elsevier Inc. All rights reserved.
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    Characterization of Properties in Friction Welded Stainless Steel and Copper Materials
    (Springer, 2013) Sahin, Mumin; Cil, Ender; Misirli, Cenk
    The aim of this study is to investigate the metallurgical and mechanical properties of friction welded stainless steel-copper joints. One of the manufacturing methods used to produce parts made from different materials is the friction welding method. Application of classical welding techniques to such materials is difficult because of they have different thermal properties. Stainless steel-copper joints are inevitable for certain applications due to unique performances such as higher electric conductivity, heat conductivity, corrosion resistance, and mechanical properties. In the present study, austenitic stainless steel and copper parts were joined by friction welding. Tensile, fatigue, and notch-impact tests were applied to friction welded specimens, and the results were compared with those for the original materials. Microstructure, energy dispersive x-ray, and x-ray diffraction (XRD) analysis and hardness variations were conducted on the joints. Results showed that various intermetallic phases such as FeCu4 and Cu2NiZn occurred at the interface. It was found from the microstructure and XRD analysis that intermetallic phases formed in the interface which further caused a decrease in the strength of the joints. However, hardness of the copper increased slightly, whereas the hardness of steel decreases slightly on the horizontal distance from the center.
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    Characterization of properties in friction-welded austenitic-stainless steel and aluminium joints
    (Emerald Group Publishing Ltd, 2014) Sahin, Mumin
    Purpose - The main purpose of the present study was to evaluate the metallurgical and mechanical properties of dissimilar metal friction welds (FWs) between aluminium and type 304 stainless steel. Design/methodology/approach - One of the manufacturing methods used to produce parts made from different materials is the FW method. Therefore, in the present study, austenitic stainless steel and aluminium parts were joined by FW. Tensile, fatigue and notch-impact tests were applied to FW specimens, and the results were compared with those for the original materials. Microstructure, energy dispersive X-ray (EDX) and X-ray diffraction (XRD) analysis and hardness variations were conducted on the joints. Findings - It was found from the microstructure and XRD analysis that inter-metallic phases formed in the interface which further caused a decrease in the strength of the joints. Research limitations/implications - In this study, the rotation speed was kept constant. The effects of the rotation speed on the welding quality can be examined in future. It is important to note that the FW process was successfully accomplished in this study although it was particularly difficult to obtain the weld due to the large deformations at the interface. Practical implications - Low-density components such as aluminium and magnesium can be joined with steels owing to being cost-effective in industry. Application of classical welding techniques to such materials is difficult because they have different thermal properties. Their welding plays a key part in industrial quality and process control, in the efficient use of energy and other resources, in health and safety. Then, this study will contribute for welded, brazed and soldered materials. Originality/value - The main value of this paper is to contribute and fulfill the influence of the interface on properties in welding of various materials that is being studied so far in the literature.
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    Characterization of properties in plastically deformed austenitic-stainless steels joined by friction welding
    (Elsevier Sci Ltd, 2009) Sahin, Mumin
    Friction welding is widely used as a mass-production method in various industries. Welding is used for joining parts with equal and/or different diameters. Austenitic-stainless steels are preferred over other stainless steels due greater ease in welding. In the present study, an experimental set-up was designed in order to achieve friction welding of plastically deformed austenitic-stainless steels. AISI 304 austenitic-stainless steels having equal and different diameters were welded under different process parameters. Strengths of the joints having equal diameter were determined by using a statistical approach as a result of tension tests. Hardness Variations and microstructures using scanning electron microscope (SEM) analysis in the welding zone were obtained and examined. Subsequently, the effects on the welding zone of plastic deformation was analysed. It has been established that plastic deformation of AISI 304 austenitic-stainless steel has neither an effect on the process nor on the strength of the welding joint. (C) 2008 Elsevier Ltd. All rights reserved.
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    Determining the influence of surface roughness on materials flow of various materials using grid lines during cold forming
    (Emerald Group Publishing Limited, 2010) Cetinarslan, Cem S.; Sahin, Mumin
    Purpose - The purpose of this paper is to determine the influence of surface roughness on materials flow of various materials using grid lines during cold forming. Design/methodology/approach - The study is focused on the investigation of the influence of the surface roughness on the materials flow for different materials using grid lines in the upsetting. Stainless steel, SAE 1020 steel, commercially pure aluminum, commercially pure copper and CuZn(40)Pb(2) brass are used as the test materials. Upsetting process is applied to the cylindrical specimens using the flat end dies. Strain distributions on the free surfaces of cylindrical upset specimen are measured for different upsetting reductions. Strain distributions on the free surfaces are obtained by the measurements of the dimensions of the square grid elements before and after the upsetting process. Experimental results are placed into graphical plots. Findings - It is found that surface roughness is effectual on the strain changes on the free surfaces with the increasing deformation ratio for especially two types of steel specimens. There has been no considerable effect on aluminum, copper and brass specimens. Research limitations/implications - It would be interesting to search the surface roughness, R(sk) and other parameters describing the bearing properties of the surface of more materials. Future work could be concentrated on the cold forming of these materials. Practical implications - Different forming technologies are nowadays widely applied in mass production of mechanical components for needs of transportation, electronics, household appliances, etc. In order to reduce costs, manufacturers are trying to minimize additional machining and therefore to implement the influence of surface roughnesses on materials flow of various materials. Originality/value - The main value of this paper is to contribute to studies on the influence of surface roughness on materials flow of various materials.
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    Effect of surface roughness on friction coefficients during upsetting processes for different materials
    (Elsevier Sci Ltd, 2007) Sahin, Mumin; Cetinarslan, Cem S.; Akata, H. Erol
    Presented study is focused on the investigation of the effect of the surface roughness on the frictional properties for different materials and conditions. Three types of steel, commercially pure aluminium and annealed CuZn40Pb2 brass were used as the test materials in the experimental part of the study. Ring compression test procedure was applied to the specimens using flat end upsetting dies. Dimensional changes of the specimens after the tests were measured in order to obtain the variations of the increments in the inner diameters versus upset ratios. Experimental results were placed into ring compression calibration curves for each of the material type and surface conditions. Roughness measurements were carried out using a digital roughness meter. Upsetting tests were carried out using a hydraulic press of 150 metric tons with 5 mm/s ram speed. (c) 2005 Elsevier Ltd. All rights reserved.
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    Effect of surface roughness on weldability in aluminium sheets joined by cold pressure welding
    (Emerald Group Publishing Limited, 2008) Sahin, Mumin
    Purpose - The purpose of this paper is to examine the effects of the welding deformation and surface roughness in cold pressure welding on the tensile strength and the fatigue strength of joined sheets. Additionally, the paper seeks to analyse the hardness variations and microstructures at the welding interface. Design/methodology/approach - Cold pressure welding is a method of joining similar or dissimilar ductile metals. it can be applied by bringing into close contact the surfaces of virgin metal specimens that appear due to the breakdown of the surface layers caused by bulk plastic deformation. Cold pressure welding is applied to test parts without too long a delay after the preparation of surfaces. The application of welding in 10 min affects importantly the weld strength. As this time is increased, the weld strength of the joints is decreased. The determination of deformation amount is found by determination of the reduction (R) at the total thickness of the two parts after the welding process. Findings - The weld strength increases as the surface roughness and weld deformation of the joined sheets increase. The length of bond zones increases with increasing deformation. Therefore, the weld strength of parts depends on the length of bond zones. Then, there is an effect of surface roughness on the welding strength. Joined sheets show resistance to little fluctuating tensile stress. It is observed that the parts rupture from the welding-interface hardness values are about the same at interfaces of sheets having different surface roughness and equal deformation (60 per cent). But, if it is considered that hardness of aluminium material purchased is about 53 HV, it can be said that the hardness increases in joined parts because of local hardening during deformation in cold pressure welding method as lap welding. Bond formation at interfaces of joined sheets having R-a = 5 mu m surface roughness and deformation ratio 60 per cent is shown to be successful in the microstructure photo. Research limitations/implications - Surface roughness and deformation values can be increased in further studies. Originality/value - The paper offers insight into the effects of surface roughness on weldability.
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    The effects of casting and forging processes on joint properties in friction-welded AISI 1050 and AISI 304 steels
    (Springer London Ltd, 2009) Sunay, Tolga Y.; Sahin, Mumin; Altintas, Sabri
    The aim of the present study was to investigate the effects of investment casting and forging process on the microstructure and mechanical properties of friction weldments, AISI 1050-AISI 304. A continuous-drive friction welding device with the automatic control ability of friction time and forging pressure was designed and constructed. Factorial design of experiments was performed to join investment cast AISI 1050 steels and forged AISI 1050 steels with AISI 304 austenitic stainless steel with respect to the optimized process parameters. The joint performance was evaluated by tensile and hardness tests performed parallel and perpendicular to the weld interface. Microstructure of forged parts under friction welding was examined using optical microscopy, scanning electron microscopy, and energy-dispersive spectroscopy. Results of microstructural studies were compared with those of friction welding of investment cast parts. The results reveal that a recrystallized region or a mechanically mixed layer was formed on the AISI 304 side near the weld interface, depending on friction time and friction pressure. Friction welding of forged parts always exhibited higher tensile strength, lower hardness, and more upset than the cast parts.
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    Effects of Sintering Temperature on Microstructural Properties of Ni1-xZnxFe2O4 Synthesized by Powder Metallurgy
    (Kaunas Univ Tech, 2022) Aras, Mustafa; Sahin, Mumin; Gundogdu, Ozcan
    Powder metallurgy (PM) is a modern manufacturing method that allows high-tech materials, alloys and complex shaped parts to be manufactured with precision and almost without the need for finishing operations such as deburring. PM involves powder production, powder processing, forming operations, pressing and sintering or pressure-assisted hot consolidation. This paper reports results on Ni1-xZnxFe2O4 produced by powder metallurgy at different sintering temperatures. Ni1-xZnxFe2O4 is an interesting functional magnetic material due to its special properties such as stability, very good dielectric properties, electrical resistivity, low dielectric loss, chemical stability, etc. all being important in cutting-edge technology. The use of Ni1-xZnxFe2O4 in diverse fields such as the biomedical field i.e. drug delivery is another vibrant research area. SEM imaging was performed for the structural analysis of the produced bulk sample. EDXRF analyses were performed for elemental composition along with SEM images.
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    Evaluation of temperature and properties at interface of AISI 1040 steels joined by friction welding
    (Emerald Group Publishing Ltd, 2008) Kuscu, Hilmi; Becenen, Ismail; Sahin, Mumin
    Purpose - The purpose of this paper is to evaluate temperature and properties at interface of AISI 1040 steels joined by friction welding. Design/methodology/approach - In this study, AISI 1040 medium carbon steel was used in the experiments. Firstly, optimum parameters of the friction welding were obtained by using a statistical analysis. Later, the microstructures of the heat-affected zone are presented along with micro hardness profiles for the joints. Then, the temperature distributions are experimentally obtained in the interface of the joints that is formed during the friction welding of 1040 steels with the same geometry. This study was carried out by using thermocouples at different locations of the joint-interface. The results obtained were compared with previous studies and some comments were made about them. Findings - It was discovered that temperature had a substantial effect on the mechanical and metallurgical properties of the material. Research limitations/implications - The maximum temperature in the joint during frictional heating depends not only on the pressure, but also on the temperature gradient which depends on the rotational speed in particular. It is important to note that the measurement process was successfully accomplished in this study although it was particularly difficult to obtain temperature due to the large deformations at the interface. Future work could be concentrated on the temperature measurement of the joined materials. Practical implications - Temperature is one of the most important of all physical quantities in industry. Its measurement plays a key part in industrial quality and process control, in the efficient use of energy and other resources, in condition monitoring and in health and safety. This paper contributes to the literature about temperature measurement in welded, brazed and soldered materials. Originality/value - The main value of this paper is to contribute and fulfill the influence of the interface temperature on properties in welding of various materials that is being studied so far in the literature.
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    Evaluation of the joint-interface properties, of austenitic-stainless steels (AISI 304) joined by friction welding
    (Elsevier Sci Ltd, 2007) Sahin, Mumin
    The aim of this study is to investigate experimentally the micro-structural properties and welding strengths of the joints using austenitic-stainless steel (AISI 304) parts. The experiments were carried out using a beforehand designed and constructed experimental friction welding set-up, constructed as continuous-drive. Firstly, pilot welding experiments under different friction time and friction pressure were carried out to obtain optimum parameters using statistical approach. Later, the strengths of the joints were determined by tension, fatigue and notch-impact tests, and results were compared with strengths of materials. Hardness variations and microstructures in the interfaces of the joints were also obtained and examined. Then, obtained results were compared with those of previous studies. (c) 2006 Elsevier Ltd. All rights reserved.
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    Experimental Analysis of Welded Rods with a Functionally Graded Material Approach
    (Mdpi, 2020) Basmaci, Ayse Nihan; Filiz, Seckin; Sahin, Mumin
    In recent years, with the development of welding methods, using these methods in manufacturing industry and in advanced engineering has become more popular. In this study, mechanical properties of rods obtained by friction welding and electric arc welding are compared. Hence, three specimens with different material properties are manufactured, two of which are welded by friction welding and one of which is welded by electric arc welding. These three specimens are adapted to the ASTM E8-04 standard with the help of a universal lathe. Moreover, the tensile stress values and the elasticity modulus of all these specimens are obtained as a result of tensile tests. Accordingly, the effects of the type of welding and material properties used in manufacturing on the mechanical behavior of the specimens are examined. In addition, specimens taken from the cracked surfaces of the pieces broken from the specimens as a result of the tensile test are examined with SEM (scanning electron microscopy). These examinations reveal the microstructure of the specimens. The elemental distribution data obtained as a result of examinations with SEM and the mechanical property data obtained as a result of tensile tests support each other. Furthermore, effects of a heat affected zone (HAZ) on the mechanical properties of the rod are investigated as a functionally graded material.
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    An experimental study on joining of severe plastic deformed aluminium materials with friction welding method
    (Elsevier Sci Ltd, 2008) Sahin, Mumin; Akata, H. Erol; Ozel, Kaan
    In this study, 5083 aluminium alloys, which were exposed to severe plastic deformation, were joined with friction welding method and the variation in mechanical properties of the joints was experimentally investigated. Severe plastic deformation methods can be classified as equal channel angular pressing (ECAP) (in other words, equal cross section lateral extrusion-ECSLE) and cyclic extrusion-compression. Aluminum alloy as test material 5083 and square cross-sectional equal channel angular pressing die for severe plastic deformation were used in the study. Firstly 5083 alloys, as purchased, were joined with friction welding method. The optimum parameters for friction time, upset time, friction pressure and upset pressure, which are necessary for welding, were obtained. Afterwards, 5083 aluminium materials as purchased were prepared as square cross-section and then I-pass severe plastic deformation was applied to specimen by equal channel angular pressing die. The obtained parts as square form were prepared as cylindrical form by machining and then the parts were joined by continuous drive friction welding equipment that was designed and produced in laboratory conditions before. Later, the tensile strengths of the parts, obtained at optimum conditions, were compared with those of the joined parts as purchased form. Then, hardness variations and microstructures of joints were examined. Finally, the obtained results were commented on. (C) 2006 Elsevier Ltd. All rights reserved.
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    An investigation into reutilizing of waste materials using friction welding and upset manufacturing methods
    (Emerald Group Publishing Limited, 2007) Akata, H. Erol; Sahin, Mumin; Ipekci, M. Turan
    Purpose - The present study seeks to examine the possibilities of combined usage of friction welding and plastic forming in recycling of bar-shaped waste materials. Design/methodology/approach - if the waste materials can be reproduced using various manufacturing methods without melting, their economic values could be increased economically. For this reason, using a combination of friction welding and plastic forming was chosen as an alternative recycling method. Upsetting was chosen as the plastic forming method due to its ease of application. Findings - In the present study, dimensional changes, hardness variations in heat affected zone (HAZ), variations of torsion and tensile strengths with upsetting ratio of specimens were examined. Hardness values of test material are raised to higher levels within the HAZ by the local hardening. The maximum shear stress in torsion and the tensile strengths of specimens are closely harmonious with hardness values of test material. Research limitations/implications - Although it was observed in general that the increasing upsetting ratio increased the torsion and tensile strengths, experimental study must be improved and extended in order to obtain more precise results. Practical implications - It can be concluded that combined usage of just welded and additional cold deformation can be considered as an alternative recycling method owing to obtained positive results. Originality/value - This paper helps individuals reutilize waste materials because of the small lengths of the bars. Furthermore, it can be observed that the combination of friction welding and plastic|forming produces savings in the material and the cost in this study.
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    Investigation of properties of ion-nitrided AISI 304 austenitic-stainless steel
    (Emerald Group Publishing Limited, 2011) Sahin, Mumin; Sevil, Ceyhun
    Purpose - The aim is to provide detailed mechanical and metallurgical examinations of ion-nitrided austenitic-stainless steels. Design/methodology/approach - Austenitic-stainless steel was the material chosen for the present study. Ion nitriding process was applied to fatigue and tensile samples prepared by machining. Process temperature was 550 degrees C and treatment time period 24 and 60 h. Then, tensile, fatigue, notch-impact, hardness tests were applied and metallographic examinations were performed. Findings - High temperature and longer treatment by ion nitriding decreased fatigue and tensile strengths together with notch-impact toughness. Scanning electron microscopy and energy dispersive X-ray spectroscopy analysis revealed formation of nitrides on the sample surfaces. Surface hardness increased with an increase in process time due to diffusion of nitrogen during ion nitriding. Research limitations/implications - It would be interesting to search the different temperature and time intervals of the ion nitriding. It could be a good idea if future work could be concentrated on ion nitriding on welded stainless steels. Practical implications - Surfaces of mechanical parts are exposed to higher stress and abrasive forces compared to inside mechanical parts during the time period that mechanical components carry out their expected functions. When stresses and forces exceed the surface strength limit of the material, cracks begin to form at the material surface leading to abrasion and corrosion. Therefore, surface strength of materials needs to be increased to provide a longer service life. Ion (plasma) nitriding is a possible remedy for surface wear. Originality/value - The main value of this paper is to contribute and fulfil the detailed mechanical and metallurgical examinations of ion-nitrided austenitic-stainless steels that are being studied so far in the literature.
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    Joining of aluminium and copper materials with friction welding
    (Springer London Ltd, 2010) Sahin, Mumin
    Industrial use of non-ferrous materials is significant in the electrical and the chemical engineering applications. Copper-aluminium joints are inevitable for certain applications due to unique performances such as higher electric conductivity, heat conductivity, corrosion resistance and mechanical properties. Friction welding is the most common method used due to material and energy saving. In the present study, copper and aluminium materials were joined by friction welding. Optimum parameters were obtained using a statistical approach. Tensile and microhardness tests were applied to the joints. Micro- and macrophotographs were examined. Energy dispersive X-ray analysis was used to determine the phases that occurred during welding. A grey layer was observed at the fracture surfaces of welded parts. It was considered that this layer decreased the strength of the joints.
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    Joining of stainless steel and copper materials with friction welding
    (Emerald Group Publishing Limited, 2009) Sahin, Mumin
    Purpose - The purpose of this paper is to investigate mechanical and metallurgical variations at interfaces of commercial austenitic-stain less steel and copper materials welded by friction welding. Design/methodology/approach - In this paper, austenitic-stain less commercial steel and copper materials are welded using the friction welding method. The optimum parameters are obtained for the joints. The joints are applied to the tensile and micro-hardness tests. Then, micro- and macro-photos of the joints are examined. Findings - It is found that some of the welds show poor strength depending on some accumulation of alloying elements at the interface result of temperature rise and the existence of intermetallic layers. Research limitations/implications - It would be interesting to search about the toughness values and fatigue behaviour of the joints. It could be a good idea for future work to concentrate on the friction welding of these materials. Practical implications - Friction welding can be achieved at high-production rates and therefore is economical in operation. In applications where friction welding has replaced other joining processes, the production rate has been increased substantially. Originality/value - The main value of this paper is to contribute to the literature on friction welding of dissimilar materials.
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    Joining of stainless-steel and aluminium materials by friction welding
    (Springer London Ltd, 2009) Sahin, Mumin
    The joining of dissimilar materials is of great importance in industry. Especially, if it is used as the lightest part of the machine parts, materials such as aluminium and magnesium can be joined with different steels. Therefore, in this study, austenitic stainless-steel and aluminium materials were welded using the friction welding method. Optimum parameters for joints were obtained by using a statistical approach, and tensile and micro-hardness tests were applied to the joints. Subsequently, the micro and macro photos of the joints were examined. The joints were examined with EDX (energy dispersive X-ray) analysis in order to determine the phases that occurred during welding. Some of the welds had poor strength due to the accumulation of alloying elements at the joint interface. The obtained results were compared to the results of previous studies.
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    Materials flow for different lubricants during cold forming
    (Emerald Group Publishing Ltd, 2013) Sahin, Mumin; Cetinarslan, Cem; Misirili, Cenk
    Purpose - Barreling contour variations on the free surfaces of cylindrical upset specimen are to handle measuring for different upsetting reductions and different lubrication conditions in this study. The purpose of this paper is to address this issue. Design/methodology/approach - The materials flow for various materials using different lubricants in upsetting was investigated in this study. SAE 1020 steel, commercially pure copper and CuZn40Pb2 brass were used as the:test materials. Upsetting process was applied to the cylindrical specimens using flat end dies. Three types of lubricants, namely grease, graphite and SAE 40 oil, were used in this study. Experiments were performed using a hydraulic press, which has 5 mm/s ram speed, and with a capacity of 150 metric tons. Findings - Variations of barrel radius change clearly with increasing deformation ratio depending on lubricant type. Radius values are different to each other for SAE 1020, Cu and brass specimens. It was understood that surface roughness effect is negligible at material types. The highest radius values were obtained for the brass among all the materials for the same deformation ratio. The materials flow is hard for brass specimens because of its brittleness which is due to cold drawing so its barrel radii are high. On the contrary, SAE 1020 and copper are more suitable for the plastic deformation. As shown in the Figures, the higher radius values were obtained especially with grease lubricant for brass specimens. Research limitations/implications - It would be interesting to search material flow for different materials and lubricants. It could be a good idea for future work could be concentrated material flow on upsetting using different lubricants. Practical limitations - The friction at the faces of contact retards the plastic flow of metals and the surfaces and in its vicinity. A conical wedge of a relatively undeformed metal is formed immediately below it, while the rest of the cylinder metal suffers high strain hardening and bulges out in the form of a barrel. This demonstrates that the metal flows most easily towards the nearest free surface which is the point of least resistance. However, the use of lubricants reduces the degree of bulging and under the conditions of ideal lubrication, the bulging can be brought down to zero. Originality/value - The main value of this paper is to contribute and fulfil the detailed the dependency of barrel radius on material type by upsetting of specimen of various materials using different lubricants that are being studied so far in the literature.