DISSIMILAR WELDING OBJECTIVES.

What is Dissimilar metal welding ? Need for dissimilar welding. Factors to be considered. How the factors affect the weld quality. Methods to tackle the constraints. Dissimilar welding in ICF.

What is dissimilar metal welding

Dissimilar Metal Welding, as the name implies, is joining of two metal components having different properties. A Successful weld between dissimilar metals is one that is as strong as the weaker of the two metals being joined, i.e., possessing sufficient tensile strength and ductility so that the joint will not fail in the weld

Dissimilar metal combinations

Low Alloy Steel with Low Alloy Steel High Alloy Steel with High Alloy Steel

High Alloy Steel with Low Alloy Steel

Low Alloy Steel with Non-ferrous

RAILWAY APPLICATION
Joining of Mn-Steel Liner to Bogie/Axle Box Joining SS Steel to Mild Steel in Coaches Joining Corten Steel to Mild Steel in Coaches Joining High Tensile Steel to Mild Steel in Coaches LHB Coaches- Shell - SS Bogie - St52 Underframe - Corten Steel Others - Mild Steel

The term DISSSIMILAR has a broad meaning.

It includes:
1. Two Metals those are chemically different like Fe, Cu, Al, Ni etc. 2. Two Metals those are metallurgically different i.e. same metal with varying chemistry & properties like Mild Steel, Low Alloy Steel, Stainless Steel or Brass, Bronze etc. Dissimilar metal joining by brazing or by solid state welding process( Friction welding,Diffusion Bonding,Explosive Welding, Ultrasonic Welding) is feasible in most combination.

But, when Fusion Welding Processes are used, success depends on several factors.

Need for a dissimilar weld

Improving component properties (mechanical, physical , metallurgical) to suit service requirements structural stability. Cost factor (optimizing cost with service benefit). Aesthetics (durability , corrosion resistance)

Important Factors (constraints)

Alloying problems Differing Melting Points Differences in coefficients of thermal expansion Differences in thermal conductivity Service considerations

Dilution ..
Filler metal should readily alloy with base metals to produce a continuous ductile matrix phase. The weld metal microstructure shall be stable , i.e, metallurgical compatibility with the base metals. Dilution should be as low as possible.

Dilution ..
AWS formula for calculating the avg. % of any specific alloying element in the diluted weld metal.. Xw = (DA) (XA) + (DB)(XB) + (1 DT)(XF) Xw , XA , XB - avg % of element X in weld metal, metal A & metal B respectively XF - avg % of element X in Filler metal DA percent dilution by base metal A , DB percent dilution by base metal B DT percent total dilution by base metals A & B

Factors affecting Dilution

Welding process Filler metal Type of metal transfer ( spray transfer gives the
greatest dilution and short circuit transfer the least dilution).

Joint design and fit up.