Optimization of Electron Beam Welding Parameters of Dissimilar Joint of Aisi 304 Stainless Steel and Aisi 1020 Low Carbon Steel

Abstract

This paper presents the optimization of welding parameters of electron beam welded joint of dissimilar materials namely AISI 304 stainless steel and AISI 1020 low carbon steel (0.21% C.). Three main welding parameters were investigated. These parameters are welding current, focusing current, and welding speed. The optimization was based, from one hand, on microstructure analysis of both bead and heat affected zones, using optical and scanning electron microscopes, and, from the other hand, the evaluation of tensile, impact, and micro-hardness mechanical properties. The results of the investigation showed that, an optimum welding current of 19 mA, a focusing current of 875 mA, and a welding speed of 8mm/s at a working distance 100 mm can provide uniform welding bead with full penetration, without undercuts and a narrow width of HAZ in the order of 2.3 mm. Moreover, they can secure a tensile failure outside the joint, in the base metal (low carbon steel) satisfying a tensile strength of about 430 MPa. Furthermore, the impact resistance of the joint was found to provide about 160 J/cm 2 (hummer against the root of bead) and about 70 J/cm 2 (hummer against the face of bead). The hardness distribution along the joint from the stainless steel side to the low carbon steel side through the bead and HAZ was determined, and indicates that, a maximum hardness of about 380 HV was obtained in the center of the bead. This value is higher than the obtained hardness values of both the austenitic stainless steel and low carbon steel.

Numerical and experimental study for electron beam welding process of Al6061-T6 material

“…They emphasized the importance of parameter study in narrowing the HAZ and increasing the strength of the welding region; according to the experimental design, they applied EBW for AA1350 alloy, a material with low weldability. Nasr El-Deen et al [16] focused on optimizing EBW parameters for AISI 304 stainless steel and AISI 1020 materials. As a result of the study, they reported that the energy of the beam current has a significant effect on the characteristic properties of the welded joint.…”