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<p>This study investigated arcing wire gas tungsten arc welding (AW–GTAW) for copper–steel dissimilar cladding, focusing on low-heat input, droplet transfer behavior, and interfacial evolution in comparison with MIG welding . Results indicated that AW–GTAW achieved decoupled bypass/main current control, enabling precise droplet regulation while reducing the peak temperature by 27% and dilution rates by fourfold compared to MIG. At a bypass current of 90&#xa0;A, stable globular transfer was dominant; increasing to 195&#xa0;A transitioned the process to spray transfer, achieving a cladding speed of 13.6&#xa0;m/min. Microstructural analysis demonstrated that AW–GTAW effectively suppressed Fe diffusion into the cladding layer, considerably reducing the number of Fe-enriched dendritic structures compared to MIG. Nanoindentation analysis confirmed superior interfacial mechanical properties in AW–GTAW, which exhibited an elastic modulus of 2.01 × 10^11 N/m<sup>2</sup> and a contact stiffness of 1441.2 N/m. Moreover, under identical process parameters, the cladding hardness obtained by AW–GTAW was considerably lower (2.67&#xa0;GPa) than that of MIG (3.19&#xa0;GPa), with increased bonding strength due to minimized thermal stress. These findings establish AW–GTAW as a high-potential technique for precision copper–steel cladding.</p>

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Interfacial Microstructure and Process Optimization in Copper-Steel Cladding via AW–GTAW: A Comparative Study with MIG Process

  • 期刊论文

  • 发表日期：

    2025年11月18日

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  • BoHao Li,
  • WenZhuo Bian,
  • ShiHu Zhen,
  • Jun Wang,
  • HuiXia Wang,
  • Kai Fu,
  • Liang Zhang

摘要

This study investigated arcing wire gas tungsten arc welding (AW–GTAW) for copper–steel dissimilar cladding, focusing on low-heat input, droplet transfer behavior, and interfacial evolution in comparison with MIG welding . Results indicated that AW–GTAW achieved decoupled bypass/main current control, enabling precise droplet regulation while reducing the peak temperature by 27% and dilution rates by fourfold compared to MIG. At a bypass current of 90 A, stable globular transfer was dominant; increasing to 195 A transitioned the process to spray transfer, achieving a cladding speed of 13.6 m/min. Microstructural analysis demonstrated that AW–GTAW effectively suppressed Fe diffusion into the cladding layer, considerably reducing the number of Fe-enriched dendritic structures compared to MIG. Nanoindentation analysis confirmed superior interfacial mechanical properties in AW–GTAW, which exhibited an elastic modulus of 2.01 × 10^11 N/m2 and a contact stiffness of 1441.2 N/m. Moreover, under identical process parameters, the cladding hardness obtained by AW–GTAW was considerably lower (2.67 GPa) than that of MIG (3.19 GPa), with increased bonding strength due to minimized thermal stress. These findings establish AW–GTAW as a high-potential technique for precision copper–steel cladding.