Gas Tungsten Arc Welding of

Stainless Steel and Commercially

Pure Titanium using Copper as a
Transition Metal

Submitted by: Under the supervision of :

Deepak Kumar Dr. M. Z. Khan
Roll No.: 15132019 Associate Professor
M.Tech Production Department of Mechanical Engineering
Engineering, 4th Semester Indian Institute of Technology, BHU
Varanasi 221005
1
 Contents
1. Introduction
2. Literature Review
3. Material Selection
4. Initial Trials
5. Reasons of the failure of experiments
6. Proposed solutions
7. Adopted solution
8. Reasons of selecting Copper
9. Experimentation
10. Results
11. Conclusions
12. Scope of Future work
13. References

2
 Introduction
In recent years, joining of dissimilar metals is gradually investigated because it is
capable of offering complex functions and finding applications in variety of fields
such as thermal power station, nuclear industries, petrochemical industries,
aerospace, microelectronics, automobile etc.
For example, aluminium and magnesium alloys are used by automobile industries
because they are attractive as lightweight structural materials to achieve high
performances and efficiency. However, steels are still widely used as structural
materials due to their high absolute strength and good cost efficiency. Therefore , it
is becoming very important to join Al or Mg alloys to steel to fabricate structural
components, and dissimilar welding technology is necessary.
With the increasing use of Ti and its alloys in aerospace, transportation, power
generation and chemical industries because of their high strength to weight ratio
and excellent corrosion resistance, there is an obvious requirement to join them to
other dissimilar metals.

3
 Introduction
In particular, the joining of Ti to structural steels with high strength and toughness
is of considerable importance for the integration and fabrication of Ti-base
components, although a conventional fusion welding has not been technically
usable.

Titanium to stainless steel joints have applications in chemical and nuclear industry.

4
 Literature Review
Table.1: List of researches performed in past 2o years

No. Date Authors Materials Method

1 2016 Supriyo et al. CP Ti to SS 304 GMAW
2 2012 Zhang et al. Ti-15V-3Al to SS 304 EBW
3 2012 Shanmugarajan et al. CP Ti to SS 304 LW
4 2012 Gao et al. Ti-6Al-4V to SS 304L LW
5 2011 Tomashchulk et al. Ti-6Al-4V to SS 316L LW
6 2011 Fazel-Najafabadi et al. CP Ti to SS 304 FSW
7 2011 Akbarimousavi et al. CP Ti to SS 316 L FW
8 2010 Wang et al. Ti-15V-3Al to SS 304 EBW
9 2010 Liao et al. CP Ti to steel FSW
10 2010 Fazel-Najafabadi et al. CP Ti to SS 304 FSW
11 2010 Kundu et al. CP Ti to SS DB
12 2009 Mousavi et al. CP Ti to SS 304 EW
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 Literature Review
Table.2: List of researches performed in past 2o years

No. Date Authors Materials Method

13 2009 Elrefaey et al. CP Ti to steel DB
14 2009 Elrefaey et al. CP Ti to steel DB
15 2009 Dey et al. CP Ti to SS 304 FW
16 2008 He et al. Ti-6Al-4V to SS DB
17 2005 Kahraman et al. Ti to SS EW
18 2005 Ghosh et al. Ti-6Al-4V to SS 304 DB
19 2005 Ghosh et al. Ti-6Al-4V to SS 304 DB
20 2005 Kundu et al. CP Ti to SS 304 DB
21 2004 Lee et al. CP Ti to SS 321 FW
22 2003 Mudali et et al. CP Ti to SS 304 EW
6
 Literature Review
Methods used to Titanium and Stainless steel in past 20 years

Electron Beam Welding

Laser Welding
Friction Stir Welding
Friction Welding
Diffusion Bonding
Explosive Welding
Arc Welding/Brazing

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 CP Titanium
Table.3: Properties of CP Titanium

CP Titanium: Physical Properties

Titanium has combination of interesting Density 4.506 g/cm3
properties.
Melting Point 1688 oC

Low density
Mechanical Properties

High melting point Yield Tensile Strength 275-410 MPa

Ultimate Tensile Strength 345 MPa (min)

Superior mechanical properties Vickers Hardness 145 HV

Thermal Conductivity 16.4 W/(m.K)

Satisfactory specific strength (high tensile Thermal Expansion Coefficient 8.6 m/(m.K) (at 25 oC)
strength/weight ratio)

Outstanding corrosion resistance. Chemical Composition

Fe 0.2

C 0.08

However, the use of titanium is limited by its N 0.03

high cost and the problems of joining the H 0.015
metals/alloys to other substances such as steel O 0.25 8
and stainless steel.
Rest Ti
 Stainless Steel (SS 304) Table.4: Properties of SS 304

SS 304: Physical Properties

In metallurgy, stainless steel is also known as Inox Density 8 g/cm3

steel. SS 304 is the most widely used austenitic Melting Point 1400-1455 oC

steel also known as 18/8 for its composition of Mechanical Properties

18% chromium and 8% nickel. Yield Tensile Strength 215 MPa

Ultimate Tensile Strength 505 MPa

It is known for its corrosion resistance and Vickers Hardness 129 HV
generally used for food handling or cutlery Thermal Conductivity 16.2 W/mK
applications. SS 304 is austenitic steel and has an
Thermal Expansion Co- 17.3 m/(mK) (at 20 oC)
austenitic crystalline structure, which is face-
efficient
centered cubic crystal structure.
Chemical Composition

It has also wide applications in architectures, C Max 0.08

bridges, monuments and sculptures and Cr 18-20

locomotives. Fe 66.345-75

Mn Max 2

Ni 8-10.5

P Max 0.045

S Max 0.03

9 Si Max 1
 Initial Trials
Initially we tried to weld commercially pure
titanium and stainless steel (SS 304) plates,
both having dimension of 100 mm*50 mm*2
mm using GTAW welding in butt joint fashion
without any filler on interlayer metal at given
parameters.

We varied the position of arc in all three

samples, first weld is performed with arc on
the titanium side, second weld is performed
with arc on the stainless steel side and third
weld is performed with arc on middle of both
the plates.
Table.5: Welding process parameters for initial trials
Sample no. Current (A) Welding speed Electrode dia. (mm)

(mm/sec)

1 145 2 2.4

2 160 3 2.4

3 181 4 2.4 Figure.1: Front and back view of gas tungsten arc welded
sample 3 without any filler metal.
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 Reason for the failure of experiment
From table as well as binary
phase diagram, we can see
the possible phases which
can be formed. From further
study we found that two of
the phases TiFe and TiFe2 is
very hard and brittle in
nature.
Table.6: Phases forms during interaction of
Fe and Ti at different wt%

Phase Composition, wt% Fe

Ti 0 to 0.047

Ti 0 to 24.7

TiFe 51.3 to 54.1

TiFe2 68.2 to 75.4

Figure.2: Fe-Ti binary phase diagram [1]
Fe 91.3 to 100
11
Fe 99.5 to 100
 Reason for the failure of experiment

We analyzed the Meas. data:2

obtained curve in JSPD 8.0e+003

software and matched

with the database and
6.0e+003

Intensity (counts)
find the phases
formed.
4.0e+003

Analysis confirmed the

formation of TiFe and 2.0e+003
TiFe2 intermetallic
compound at the weld
0.0e+000
bead. 20 40 60 80 100 120
2-theta (deg)

Figure.3: XRD spectrum of GTAW welded sample without any filler

metal.

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 Proposed solution of the problem
Weld Process Control
Weld Metal Engineering

13
 Adopted solution of the problem
Our present work proposed weld metal engineering technique to
improve the mechanical properties of titanium to stainless steel welded
joint.

Copper was selected as transition metal due to its lower melting point vs
mechanical properties relationship when compared to other transition
metal like Ag and Ni. Cu is compatible with Fe, and the intermetallic
compounds produced with Ti are tougher than Fe-Ti intermetallic
compounds

It is also a very economical option compared to other filler options.

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 Reasons for selecting Copper
From ternary phase
diagram, we got to know
about different intermetallic
compounds possibilities
between these three
elements. We studied about
the properties of the
intermetallic compounds
and found that its tougher
than the Fe-Ti intermetallic
compounds and good
affinity towards each other.

Figure.4: Ti-Cu-Fe ternary phase diagram [1]

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 Reasons for selecting Copper
Miedema model when two metals collide, the transformation into a new phase occurs
and which lowers the energy of a system. If the initial stage is unstable, a transformation
to a new more stable state occurs. According to thermodynamics, bond is stable when
the Gibbs free energy (G) is low whose change (G) during the process is given by

Where H is the enthalpy, T is the atmospheric temperature and S is the entropy. In solid
state bonding, change in enthalpy is equal to change in Gibbs free energy as entropy is
the order of 0.001 kJ/deg/mol [10] and hence

So from Miedemas equation and plot we found that enthalpy difference between Cu-
Steel is positive (H= +60kJ/mole) and same goes for enthalpy difference between Cu-
Ti which is also positive. So it proves that the tendency of formation of intermetallic
compounds is low for Cu-Steel and Cu-Ti. So it verified our choice of taking copper as a
transition metal between commercially pure titanium and stainless steel.

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 Copper
Pure copper is tough, malleable Table.7: Properties of Commercially Pure Copper.

and ductile. Copper is a good Copper: Physical Properties

conductor of electricity and
heat.
Density 8.96 gm/cm3

This is used for automotive Melting Point 1084.62 0C

radiators, heat exchangers, and

home heating systems. Mechanical Properties

They are also ideal for solar

Yield Tensile Strength 70 MPa
collectors and various other
applications requiring rapid Ultimate Tensile Strength 220 MPa

conduction of heat across a Vickers Hardness 343-369 MPa

metal section. Because of their Thermal Conductivity 401 W/(m*K)
outstanding ability to withstand
Thermal Expansion Coefficient 16.5 m/(m*K) (at 25 0C)
corrosion, they are also used
for pipes, valves and fittings.

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 Experimentation
A thin copper piece of rectangular cross-section is place between CP Titanium-and
SS 304 plates, both having dimension of 100 mm*50 mm*2 mm. Whole
arrangement is placed over the copper backing plate. Copper fillers height is taken
3mm and width is varied from 0.1 mm to 3.5 mm for automatic gas tungsten arc
welding.

Figure.5: Gas tungsten arc welding setup [source IDC workshop IIT (BHU) Varanasi]
18
 Experimentation

Figure.6: Front view of welding trolley and welding torch setup Figure.7: Arrangement of CP Titanium and stainless steel 304
with clamping arrangement. plate with copper strip having copper as a backing plate.

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 Experimentation

We varied the width of Table.7: Automatic GTAW Welding Parameters

copper strip throughout Parameters Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Sample 6

the experiment at
different parameters. We Current Ampere Rating 160 160 120 120 120 140

tried to achieve the joint (A)

with minimum thickness
Copper filler dimension
of copper to maximize
the strength of the joint a) Width (mm) 1.5 2.5 2.0 3.0 3.0 2.8

but at the same time a) Thickness (mm) 3.0 3.0 3.0 3.0 3.0 3.0
without any formation of
Welding Speed (mm/s) 3 3 2 1 2 2
intermetallic compounds
between titanium and 2% Thoriated Tungsten 2.4 2.4 2.4 2.4 2.4 2.4

iron. Electrode Diameter

(mm)

Argon Gas Flow Rate

(Kg/s)
20
 Results of welded sample
Front view Back view

Sample 2

Sample 3

Figure.8: welded samples

21
 Metallographic analysis

Sectioning Mounting Grinding Polishing Etching

22
Results of optical microscopy

Figure.9: SS-Cu boundary (100X) Figure.10: SS-Cu boundary (100X) showing three different
zones
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Results of optical microscopy

Figure.11: Martensic steel globules Figure.12: Cu-Ti boundary (100X)

24
Results of optical microscopy

Figure.13: Cu-Ti boundary (200X) Figure.14: Ti HAZ zone (100X)

25
 Results of Scanning Electron
Microscopy

Cu
Cu SS 304
Ti

SS 304

Figure.15: Cu-SS SEM image Figure.16: Ti-Cu-SS SEM image

26
Results of Scanning Electron
Microscopy

Figure.17: SS globules-Cu Figure.18: Ti-Cu boundary

27
Results of Scanning Electron
Microscopy

Figure.19: Ti-Cu boundary showing intermetallic formation

28
 Results of EDS

Figure.20: Showing EDS taken over the intermetallic layer

29
Results of EDS

Figure.21: EDS taken on steel globules 30

 Results of Micro-hardness
Graph.1: Variation of micro-hardness with distance from center of
the weld bead
450
400
350
Vickers Hardness in HV

300
250
Sample 2
200
Sample 3
150
100
50
0
-4 -3 -2 -1 0 1 2 3 4
31
Distance in mm
 Results of Tensile Test
4.5

3.5

Load in kN
2.5

Sample 2 Loa

1.5

0.5

0
0 2 4 6 8 10 12
Displacment in mm

Graph.2:. Load Vs Displacement

Figure.22 : showing UTM and welded sample 32

 Conclusions
It is possible to join Stainless steel 304 and Commercially Pure Titanium using
copper as a buffer material.

Heat input and rate of heat input is revealed to be a very important parameter
during the study. The maximum tensile strength is obtained for the sample which
is welded at higher heat input rate. Samples which are welded at low heat input
did not wet properly the parent metals and which results in very low mechanical
properties.

Even after the use of copper as a buffer material, formation of intermetallic

compounds couldnt be avoided, but the intermetallic formed is more ductile in
nature compared to Fe-Ti intermetallic.

33
 Conclusions
Intermetallic phases identified are mainly located at the boundary between the
parent metals and copper.

Tensile strength of the welded sample is quite low compared to the parent metals
and instead of copper, other metals like tantalum, vanadium or sandwich of
tantalum, vanadium and bronze can also be used to achieve better strength.

34
 Scope of future work
Optimization of parameters with current ampere supply, welding speed and
copper transition metal can be achieved with the aim of achieving higher tensile
strength.

For welding stainless steel to titanium through GTAW welding, a copper filler wire
can be used also instead of a sandwiched setup and to avoid mixing of titanium
and iron, a groove joint can be designed with an overlay of copper material over
stainless steel plate to avoid from mixing to titanium.

Different transition materials like tantalum, vanadium, bronze can be tried which
can result into higher joint strength and better compatibility.

35
 References
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THANK YOU

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