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<p>This study investigates the mechanical and microstructural behavior of dissimilar metal joints between copper and stainless steel fabricated using ATIG welding. Difficulties related to joining dissimilar materials have been alleviated by applying appropriate heat distribution based on the thermal requirements of the work plates and, where necessary, using flux to control spattering, due to the high thermal diffusivity of copper, which is greater than that of stainless steel (SS). Heat is distributed by offsetting the arc toward Cu, and silicone-based anti-spatter is used to control the spattering. Boron carbide (B<sub>4</sub>C) is used to improve weldability and counteract the effects of ferro present in the filler SS310; additionally, B<sub>4</sub>C is more effective in refining grains and scavenging oxygen. The primary aim is to enhance weld penetration and interfacial bonding by applying Boron Carbide (B<sub>4</sub>C) flux and SS310 filler material. Many trials were conducted, followed by hardness profiling and detailed microstructural analysis using optical microscopy. Ultimately, ATIG is performed in two passes. In the first pass, the torch is offset toward the copper (Cu), and in the second pass, without offsetting the torch, the joint is completed. The experiment was conducted welding three different SS grades (J4-16Cr, 304, and 316) with copper. Observation incorporated the micro-Vickers hardness of the weld bead for copper with J4-16Cr, SS304, and SS316, respectively. Tensile estimation was performed in accordance with the hardness conversion standard (ISO 18265:2013). To study the comparison, SEM and microstructural analysis, as well as weld penetration and porosity, were also performed. The presence of alloying elements and controlled dilution contributed to enhanced mechanical strength and potential corrosion resistance. These findings demonstrate the viability of ATIG welding for joining copper to stainless steel in applications such as heat exchangers, electrical connectors, and process piping where thermal and mechanical reliability are critical.</p>

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Mechanical and Microstructure Analysis of Dissimilar Metal Joining by ATIG Welding

  • 期刊论文

  • 发表日期：

    2026年1月6日

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  • Ganesh Singh Yadav,
  • Narasimhudu Sreeramula,
  • Leeladhar Nagdeve,
  • Ashok Kumar Dewangan

摘要

This study investigates the mechanical and microstructural behavior of dissimilar metal joints between copper and stainless steel fabricated using ATIG welding. Difficulties related to joining dissimilar materials have been alleviated by applying appropriate heat distribution based on the thermal requirements of the work plates and, where necessary, using flux to control spattering, due to the high thermal diffusivity of copper, which is greater than that of stainless steel (SS). Heat is distributed by offsetting the arc toward Cu, and silicone-based anti-spatter is used to control the spattering. Boron carbide (B4C) is used to improve weldability and counteract the effects of ferro present in the filler SS310; additionally, B4C is more effective in refining grains and scavenging oxygen. The primary aim is to enhance weld penetration and interfacial bonding by applying Boron Carbide (B4C) flux and SS310 filler material. Many trials were conducted, followed by hardness profiling and detailed microstructural analysis using optical microscopy. Ultimately, ATIG is performed in two passes. In the first pass, the torch is offset toward the copper (Cu), and in the second pass, without offsetting the torch, the joint is completed. The experiment was conducted welding three different SS grades (J4-16Cr, 304, and 316) with copper. Observation incorporated the micro-Vickers hardness of the weld bead for copper with J4-16Cr, SS304, and SS316, respectively. Tensile estimation was performed in accordance with the hardness conversion standard (ISO 18265:2013). To study the comparison, SEM and microstructural analysis, as well as weld penetration and porosity, were also performed. The presence of alloying elements and controlled dilution contributed to enhanced mechanical strength and potential corrosion resistance. These findings demonstrate the viability of ATIG welding for joining copper to stainless steel in applications such as heat exchangers, electrical connectors, and process piping where thermal and mechanical reliability are critical.