Influence of Fusion Welding Processes on Microstructure and Mechanical Properties of Dissimilar Metal (AISI 304 SS-Copper) Weldment
Bikash Ranjan MOHARANA, Aezeden MOHAMED, Sushant Kumar SAHU, Susanta Kumar SAHOO, Dillip Kumar BISWAL, Tapas Kumar MOHARANA, Kamalakanta MUDULI
Abstract. Dissimilar metal welding of AISI 304 stainless steel (304 SS) and commercially pure copper (CP copper) has been taken up to understand the influence of the different fusion welding processes on microstructure and mechanical properties of the weldment. The fusion welding processes specifically involve continuous wave CO2 laser, pulsed wave Nd: YAG laser and pulsed wave tungsten inert gas (P-TIG) welding. The primary objective of the present work is to develop a successful weld between two dissimilar metals without using any filler material by different fusion welding processes. An overall comparison of the results obtained from different sets of analyses is represented. The optical image of the top surface of the weld revealed that the no spatter formation during CO2 laser and P-TIG welding process, whereas minimal spatter for Nd: YAG laser. In comparison to laser processes, the weld face formed by P-TIG welding was much wider. However, 100% penetration was achieved with all three types of welding. The average widths of heat affected zone (HAZ) found to be 10 µm and 23 µm for CO2 and Nd:YAG laser respectively. The way the microstructure changes at the fusion zone was the same in all cases. For example, copper channels form, dendrites grow epitaxially, etc. SEM pictures indicate the Cu tubular channels observed more often for P-TIG welding. The microhardness distribution in the weld zone was found to be larger than that of copper and close to that of 304 SS. The acceptable ultimate tensile stress (UTS) for dissimilar metal welding of SS-Cu couples was found 275 MPa, 278 MPa and 195 MPa for CO2 laser, P-TIG and Nd:YAG laser respectively.
Keywords
Dissimilar Metal Wedding, Microstructure Analysis, Mechanical Analysis
Published online 7/15/2026, 9 pages
Copyright © 2026 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Bikash Ranjan MOHARANA, Aezeden MOHAMED, Sushant Kumar SAHU, Susanta Kumar SAHOO, Dillip Kumar BISWAL, Tapas Kumar MOHARANA, Kamalakanta MUDULI, Influence of Fusion Welding Processes on Microstructure and Mechanical Properties of Dissimilar Metal (AISI 304 SS-Copper) Weldment, Materials Research Proceedings, Vol. 68, pp 254-262, 2026
DOI: https://doi.org/10.21741/9781644904237-34
The article was published as article 34 of the book Green Materials, Processing & Characterization
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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