WELDING

OF
DISSIMILAR
METALS

Welding Definition
A process by which a permanent
joint is made by establishing inter
atomic bonds between two or
more pieces as they are locally
heated or all over by subjecting
them to plastic deformation or by
using both heat and plastic
deformation.

Weldability

Capacity of a material to be welded

under
fabrication
condition
imposed into a specific suitably
designed structure and to perform
satisfactorily
in
the
intended
service.
The ease with which a satisfactory
weld can be made.

Dissimilar Welding

Joining
of
metals/alloys.

two

different

Necessity:

When it is required to have one part of a

component with some specific property

e.g. corrosion resistance,heat resistance etc.

Example- Air & Exhaust valve of Diesel Loco.
- S.S. toilet with Carton/MS in
lavatories in Coaches

Dissimilar
combinations

metal

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

Dissimilar Welding

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

Dissimilar Welding Methods

By Brazing
By Solid State Welding process
like Friction welding, Diffusion
Bonding,Explosive Welding,
Ultrasonic Welding
By Fusion Welding

Problems
Melting Point difference
associated
Thermal Conductivity
1.
2.
3.
4.
5.
6.
7.

Electrical Conductivity
Coefficients of Thermal Expansion
Solid solubility
Different Corrosion Property
Chemical composition & Weld metal
dilution

Problem associated
1. Difference in Melting Point

The solidification and shrinkage of

the member with a higher melting
point will introduce stresses in the
other metal, which is only partially
solidified and therefore weak, and
causes crack.

How to avoid this?

Avoid fusion welding

Butter the end of higher melting base metal by

using filler matter having melting point lies
between the joining members. Final joint made
with butter face and other base matter the filler
matter should be one which is suitable for
lower melting base metal(e.g.: Joint between
M.S. & Al)

Braze

Use solid state welding process

Problem associated
2. Difference in Thermal Conductivity
The

heat input can be right for one

and either too less or too much for
other.
This is due to difference in heat
conduction from weld pool by two
base metals.

How to avoid this?

Direct the arc towards high conductivity base
metal
Selectively preheat the base metal having high
conductivity.
Austenitic Steel has less conductivity than mild
steel whereas Cu & Al have higher conductivity
than mild steel

Problem associated
3. Difference in Electrical conductivity
The metal with high conductivity will offer less
resistance, get less heated and consequently
require more current for welding.
Ratio of electrical conductivity
Cu : Al : SS

:: 1.0 : 0.59 : 0.03

Problem associated
4. Difference in Thermal Expansion
Generation of stress at the point.
If the difference is more it can cause cracks.
Even if,a successful joint is made it can create
problems if subjected to cyclic heating.
Thermal expansion of SS is about one and half
times that of mild steel.

How to avoid this?

Design the joint in such a way that it is not
restrained.
Preheat the joint to lower the cooling rate &
Post-heat.
Peen the joint to induce plastic flow in the
weld metal.
Use a filler metal of co-efficient of thermal
expansion midway between the two base
metal & having high ductility.

Problem associated
5. Solid Solubility
If there is little or no solubility, joining of metals is
difficult.
Copper & Steel are difficult to weld; Nickel & steel is
easier because of their good solubility.
form phases other than solid solution called
intermediate phase or intermetallic which may be
harmful due to their mismatching properties,
brittleness etc. EX: A study of Al-Fe phase diagram reveals the presence of a
number of complex intermetallic, a few of which are brittle.Therefore weld would be
poor in quality.

How to avoid this?

Avoid fusion Welding.

If fusion welding is to be done , use an intermediate
metal.

Problem associated
6. Corrosion Resistance
Filler metal should be so chosen that it is
cathodic to the base metal.

Problem associated
7. Chemical Composition & Dilution
Dilution is a change in alloy content of a weld
deposit by virtue of base metal metal melting.
Dilution will be more if volume of filler metal is
relatively less.
Dilution should be as low level as possible. Dilution
depends on the welding process variables and
penetration.

How to avoid this?

In SMAW process

The current setting should be in the middle of

the range.
The manipulation of the arc near base metal.
Stringer bead

In GMAW process

speed-amperage balance should be such that

Droplet transfer is attained rather than spray
transfer.

Dilution Range of Various

Arc Welding Processes

MMAW

:25-40%

SAW

:25-50%

TIG

:20-40%

MIG (Spray Transfer) :25-40%

MIG (Dip Transfer)

:15-30%

How to avoid these?

Minimum heat input

Proper filler material compatible with

both the materials to be joined.

Process with minimum

must be chosen.

When using gas metal arc welding,

reduce current density for dip transfer
of metal.

penetration

How to avoid these?

Problem of dilution and intermetallic phases
can be minimised by buttering one or both
the joint faces with a layer of compatible
material.
In case of steels, heat treatment must be
chosen as needed by the base materials. If
one is hardenable low alloy steel the pre-weld
and Post Weld Heat Treatment appropriate to
Low Alloy Steel should be used.

How to avoid these?

Where heat treatment is not possible,

ductile austenitic filler metals must be used
in cases involving hardenable materials.
This will compensate for the lack of
ductility in the HAZ.

The PWHT corresponding to the material

which requires high temperature or long
soaking time, must be used.

Dissimilar Combinations
Low Alloy Steel with other Low Alloy Steel

strength of weaker steel and toughness of less

tough steel will be required at the joint.
Preheating and interpass temperature will
normally depend on the requirements for more
highly alloyed steel.
Use of ultra-low hydrogen type electrode (AWS
7016/7018 or IS: EB5426H3X/ EB5426H3JX) will
reduce the chance of cracking.

Dissimilar Combinations

Stainless Steel trough floor with

Mild Steel/Corten Steel

Base metal Stainless steel (304/308 type)

Filler wire type 309(25Cr/12Ni).

M4 class of IRS M: 28/02.

Dissimilar Combinations

Joining of hinges or other MS/LAS

members to SS wagons, 3Cr12 type

Filler wire type 309 (25Cr/12Ni) or 310 (25Cr/20Ni)

Dissimilar Combinations

Joining of Aluminium with steel

coat with aluminium

TIG welding with aluminium based filler wires.
Arc directed to the aluminium member.
Aluminium coating on steel thick enough to avoid
burning-off.

**