Mechanical And Metallurgical Investigation Of Tig Welded-Brazed Aluminum And Stainless Steel Disimilar Joint By Using Copper Filler Rod

Kotari, Sairam; Punna, Eshwaraiah

doi:10.51201/jusst/21/09534

Cited by 3 publications

(3 citation statements)

References 18 publications

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“…The graph suggests an improvement in joint strength with higher current and slower speed. Initially, an increase in speed boosts tensile strength, but too much speed leads to insufficient heat in the weld pool, causing incomplete penetration and a drop in tensile strength [3,23]. The Fig.…”

Section: Resultsmentioning

confidence: 99%

“…As the Welding Current was increased from 83 A to 115 A, they noticed a decrease in joint strength from 280 MPa to 171 MPa. Kotari et al employed a BCuP-4 copper filler wire for the fusion of Aluminium 6061 and Stainless Steel 304 [3]. Utilizing the Taguchi method, they varied several welding parameters: currents between 90-140 A, speeds from 100-120 mm/min, and gas flows between 8-10 l/min.…”

Section: Effect Of Gtaw Parameters On Tensile Strengthmentioning

confidence: 99%

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Investigating parametric effects during TIG welding of dissimilar metals

Abdullah,

Mehmood,

Rahman

2024

Mehran Univ. res. j. eng. technol.

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This paper explores the optimization of Tungsten-Inert-Gas (TIG) welding process parameters for creating a hybrid structure of Aluminium 6061 and Stainless Steel 304 using a copper filler rod (ER-Cu). The Welding of these two materials has industrial relevance owing to its weight reduction capabilities and environmental benefits. However, Aluminium and Stainless-Steel have different melting points and thermal properties. Aluminium has twice coefficient of thermal expansion and six times coefficient of thermal conductance as compared to Stainless-Steel. This difference often results in residual stresses and brittle intermetallic compounds in the weld region. We have chosen the Welding Current, Welding Speed, and Gas Flow Rate as input parameters, and Ultimate Tensile Strength (UTS) and Micro-hardness as response parameters. We have employed the Response Surface Methodology (RSM) using a Box-Behnken design to evaluate the influence of input parameters on UTS and Micro-hardness. Furthermore, an Analysis of Variance (ANOVA) is conducted to determine the input parameters' significance on the response parameters. Our surface plots demonstrate that UTS improves with increased Welding Current and reduced Welding Speed. Simultaneously, Micro-hardness increases with elevated Welding Speed and decreased current, up to a specific limit. The peak value of UTS (79 MPa) was observed with a Current range of 85-90 A, Speed range of 95-100 mm/min, and Gas Flow Rate of 14.5-15 l/min. On the other hand, maximum Micro-hardness (260HV) was obtained with a Current range of 80-85 A, Speed range of 105-110 mm/min, and Gas Flow Rate of 14.5-15 l/min. This research contributes to improving the manufacturing process of hybrid structures, specifically by optimizing the advantages of both Aluminium and Stainless Steel while addressing the challenges that arise during their combination. The study's conclusions have major consequences for sectors looking to take advantage on the mutually beneficial characteristics of different metals in welding applications.

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Section: Resultsmentioning

confidence: 99%

Section: Effect Of Gtaw Parameters On Tensile Strengthmentioning

confidence: 99%

Investigating parametric effects during TIG welding of dissimilar metals

Abdullah,

Mehmood,

Rahman

2024

Mehran Univ. res. j. eng. technol.

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“…Due to the high Si content in filler metal, Fe diffusion in weld pool was greatly reduced, leading to a tensile strength of 208 MPa at welding current (I) of 60 A, welding speed (S) of 6 mm/s and gas flow rate (GFR) of 14 L/min. A study by Kotari and Punna [3] examined the effects of GTAW parameters and copper filler in the joining of Al 6061 and SS 304. The copper (Cu) filler metal along with Al base metal demonstrated a highly crack suppressant Al13(Fem Cun)4 solid bond and depicted a maximum tensile strength of 132 MPa at I of 100 A, S of 90 mm/min and GFR of 9 l/min.…”

Section: Introductionmentioning

confidence: 99%

Evaluation of microstructure and mechanical behavior of Aluminum 2024 and Stainless steel 304 GTAW joints

2023

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This study aims to evaluate the microstructure and mechanical behavior of aluminum 2024 and stainless steel 304 dissimilar joints. The gas tungsten arc welding (GTAW) process has been employed to weld base metals by inserting copper-nickel-based (Cu-10%Ni) filler metal. The effects of GTAW parameters such as welding current, welding speed, and gas flow on microstructure and tensile strength have been analyzed through the Taguchi method. Results revealed that tensile strength is primarily influenced by welding current, followed by speed and gas flow rate. The excellent joint strength of 138 MPa has been achieved by using Cu-10%Ni filler metal. The optimal combination of parameters, i.e., welding current of level 2 (80 A), welding speed of level 1 (100 mm/min), and gas flow rate of level 3 (10 l/min), has been obtained through SN ratio optimization. Microstructure and EDS analysis depicted that the weld zone of a high-strength joint contained fine dendrites and CuAl and NiAl solid solutions, while the weld zone of a low-strength joint featured coarse dendrites and brittle FeAl phases.

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