Effect of Electrode Diameter and Current on Dissimilar Metal Welding (Stainless Steel - Galvanized Steel) in Bus Body Construction: Microstructure and Properties Evaluation

Abstract

This study evaluates the macrostructure, microstructure, hardness, and tensile strength in dissimilar metal welding applied to bus body construction. The process involved joining hollow stainless steel and galvanized steel at the dimensions of 80 x 40 x 3.2 mm through Gas Metal Arc Welding (GMAW). The current was varied at 90, 100, and 110 A while ER70S-6 electrodes with diameters of 0.8 and 1.0 mm were used. The results showed that electrode diameter and welding current affect the capping area, penetration depth, and hardness. Moreover, the formation of the widmasatten ferrite phase was increased and the coarse grain boundaries in the weld zone were detected. It was also observed that an increase in the diameter of the electrode and the welding current which indicates an increment in the heat reduced the rate of solidification and cooling. The average tensile strength for all the samples investigated was found to be lower than the value for the base metal. Therefore, further research is recommended to improve the tensile strength.

Mitigation of Porosity and Residual Stress on Carbody Aluminum Alloy Vibration Welding: A Systematic Literature Review

“…𝑑 − 𝑑 0 𝑑 0 (7) d0 is measured at a stress-free point (that is far from the weld point). The amount of stress (σ ) can be calculated using the Equation (8).…”

“…Fatigue failure in some means of transportation is caused by the inability to withstand the load received from the car body and passengers while operating. One part with a high risk of fatigue failure is the welded joint between the frame and the car body [5]- [7]. The fatigue resistance will decrease with the formation of porosity in the weld joint [8].…”

Comparison of the accuracy of OES and EDX tests on nickel dissolving in brass casting

“…This type of permanent mold is widely used because it is very efficient to use repeatedly and is also very appropriate for mass-producing products with complex shapes [4]. The metal element to be dissolved in the base metal must be easily dissolved to fill between the alloy and other elements to achieve strength [5]. Brass alloys containing 25 % zinc and 74.8 % copper can be fused in the continuous casting method at temperatures of 950-1250 °C.…”