AbstractDue to the dynamic loads in power transmission such as automotive, the restoration of axles during maintenance is extensively needed. These parts face two main challenges: wear and fatigue failure loads. The present study tries to improve fatigue strength of C45 steel by surfacing with tungsten inert gas (TIG) welding technique using filler ER80S-B2. Fatigue life was studied through a rotary bending fatigue test at two stress levels: level I 65% and level II 55% of the ultimate tensile

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... trength of C45 base steel. Loading amplitude, coating thickness, surface roughness, and rotating speed were kept constant for all specimens. In accordance with ISO 12107, both surfaced and unsurfaced steel fatigue specimens were prepared. The specimens were tested till failure and the data were analyzed. The chemical composition, tensile strength, micro-hardness, microstructure, and fracture surface have been examined for surfaced and unsurfaced steels. Surfaced C45 steel showed improved fatigue life compared to the unsurfaced C45 steel specimens with an increasing percentage of 35.97% at level I and 25.46% at level II.