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Dissimilar joining of copper (C10300) to AISI-304 Stainless Steel (SS) sheets was performed using Electron Beam Welding (EBW) process. EBW was performed for two weld conditions such as with beam oscillation and without beam oscillation. X-ray Computed Tomography (XCT) technique was used for three-Dimensional (3D) visualization and quantification of porosity in the weld region. It was observed that the application of beam oscillation resulted in less porosity and the average pore size was found to be smaller as compared to without beam oscillation condition. Also, pores were found to be uniformly distributed in the weld incase of with beam oscillation as compared to without beam osicllaition condition. Further, it was observed that there exists an optimum beam oscillation diameter beyond which there is no positive effect of beam oscillation in controlling the porosity formation in the weld joint.

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Electron beam welding (EBW) technique was used to perform dissimilar joining of plain carbon steel to Fe-7%Al alloy under three different weld conditions such as with beam oscillation, without beam oscillation and at higher welding speed. The effect of weld parameters on the microstructure and mechanical properties of dissimilar joints was studied using optical microscopy, SEM, EBSD, hardness, tensile and erichsen cup tests.

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