Investigation of Mechanical Properties and

characteristics of copper to stainless steel

using
A-TIG Welding
Presented by:-
Ashish Rai (IU1941110005) Mechanical
Arun Yadav (IU1941110004) Mechanical

Guided by :- Dr.Dhiren Patel (Mechanical Department)

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Introduction
• Welding is applied in every industry and it’s a
major method of manufacturing and revamping
metal products because its generally economical,
efficient and reliable as a means of joining
together metals.
• This project is about to join two dissimilar metals
with the help of flux in TIG welding and analyze
Fig 1 Basic Diagram for
the mechanical & microstructure of the joints. activated TIG welding
• As there are several benefits of welding of two
metals for getting the benefits of both there
properties in Industries.
The GTAW method was employed for the
dissimilar joining of OFHC (high purity oxygen free
copper ) and AISI 304 stainless steel. The special
weld joint design of a modified socked-weld flange
with edge joints made on short-flanged edges was
used.
The butt joint of the flange edges was designed to
have different height and thickness. The welding Fig 2 Copper to SS welding
microview
was done without filler metal using a DC current of
80 A with pre-heating of the joint at 200 °C.
• The cross-sectional image of the specimen
clearly indicated the fusion zone as a
semicircular-shaped bead with the molten region
about 0.7 mm from the top.
 Principal of A- TIG welding
• Activating fluxes to improve the performance of the TIG process
were first reported by the Paton Welding Institute (PWI), Ukraine,
in the 1960's  .
• More recently, the Navy Joining Center (NJC)/Edison Welding
Institute (EWI), US, has developed an alternative range of fluxes .
Fig 3 The characteristic appearances of the activated and
conventional TIG arcs and the comparative depths of penetration
in 6mm thick stainless steel (left: Conventional TIG welding,
right: A-TIG welding)

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• The principle of the technique is that by applying a thin coating of the flux
to the surface of the material, the arc is constricted which increases the
current density at the anode root and the arc force acting on the weld pool.
• The characteristic appearance of the constricted arc compared with the
more diffused conventional welding.

Fig 4 Difference between the depth of Fig 5 Robotic Activated TIG

Conventional and activated welding Welding Layout
Materials
• Copper (Cu)
• Stainless steel(SS)
• Silicon Rod
• Flux

Fig 6 Basic processes and requirements

for the A-TIG welding 5
 Literature review
Author
Vishwa bhanu, Shailesh M
pandey, Ankur gupta,
Chandan Pandey
S. Sirohi, S. Kumar, V bhanu,
C pandey , A Gupta
Title
Dissimilar weldments of P91
and Incoloy 800HT:
Microstructure, mechanical
properties, and residual
stresses
Study on the Variation in
Mechanical Properties along
the Dissimilar Weldments of
P22 and P91 Steel
Publication
International journal of
Pressure vessels and piping
(2022)
Journal of Materials
Engineering and
Performance(2022)
6
Key observation
The capability of the weld
metal to resist the impact
load, i.e., its impact
toughness, in correspondence
to an increase in a slight
increase in tensile strength
after PWHT, was found to fall
from 96 J in AW state to 80 J
PWHT state.
The impact toughness results
also showed that the
variation along the
weldments and minimum
impact toughness was
measured 41 J in WM, which
was lower than the impact
toughness of the P22 and
P91 base metal.
Pandey, C
Sarbesh Kumar, Sachin sirohi,
RS Vidhyarthy, Ankur Gupta,
Chandan Pandey
Characterization of
Microstructure and
Mechanical Properties of Cr-
Mo Grade P22/P91 Steel
Dissimilar Welds for
Supercritical Power Plant
Application
Role of the Ni-based filler
composition on
microstructure and
mechanical behavior of the
dissimilar welded joint of P22
and P91 steel
Journal Of Materials Microstructure observation
Engineering and showed the absence of any
performance(2022) type of possible cracking in
the weldments obtained by
Inconel 82 filler; however, an
inhomogeneity in
microstructure was found
along the weldments.
International Journal Of In as-welded, the minimum
pressure vessels and Charpy impact toughness
piping(2021) (CIT) of 95.8 J was measured
in weld metal, while the
maximum was 152 J in P91
HAZ. After the PWHT HAZ
region of P22 and P91 steel
showed a drastic increase in
CIT, however reduction in CIT
of the weld metal was
measured.
Shudanshu Ranjan Singh A-TIG(activated flux tungsten International Conference on The common carrier solvent
Pradeep Khanna inert gas) Welding. Materials, Processing & are carbinol ethanol or
Characterization (2021) acetone which should be
mixed with activatee flux in
appropriate quantity so that
liquid of the paste evaporates
in the mean time leaving the
flux layer on the surface.

Basahab chandrapaul Productivity improvement in SN applied science(2021) The extent of capability of

Santanu Das butt joining of thick stainless each of the three fluxes is
steel plates through the usage analysed by comparing the
of activated TIG welding weld bead geometrical
parameters with the same
obtained. While Fe2O3 and
SiO2 fluxes are found capable
in enhancing penetration and
reducing puddle width and
heat affected zone, Cr2O3 flux
failed to exhibit better
performance.
S.A. Afolalu Investigation of mechanical International Conference on TIG welding is that which
O.M. Ikumapayi properties and Materials, Processing & creates heat with the aid of an
characterization of a joint Characterization (2021) electric arc using a non-
using nano flux powder for a- expendable tungsten electrode
tig welding to join different parts of metals
together

AR Pavan Study of arc characteristics CIRP Journal of Manufacturing High power density of helium
N Chandrashekhar using varying shielding gas and science and technology (2021) arc shielding leads to
B Arivazhagan optimization of activated-tig constricted arc column that
S kumar welding technique for thick enhances arc efficiency and
M vasudevan AISI 316L(N) plates produces deeper penetration.

Xing fei, Jian sun Microstructure and mechanical Heat Treatment and surface The microhardness of the weld
property of 738 low alloy steel Engineering 2020 metal and heat affected zone
welded joint (HAZ) obviously decreases
after PWHT. PWHT promotes
the grain growth and the
carbide precipitation, which
results in a lower impact
toughness for the PWHT joint
compared with the AW joint.
Anup kulkarni Dissimilar metal welding of P91 Journal of Material processing
Dk Dwivedi Steel-AISI 316L SS with Incoloy Technology (2019)
M vasudevan 800 and Inconel 600 interlayers
by using activated TIG welding
process and its effect on the
microstructure and mechanical
properties
R . Kumar A Review study on activatee
S. R.Sundara bharathi TIG welding of 316(L)
Austenitic Stainless Steel
G Chandrashekhar, C Investigation on un-peened
Kailashnathan And and laser shock peened
M vasundhara dissimilar weldments of
Inconel 600 and AISI 316L
fabricated using activated-TIG
welding technique
International of Journal of
Emerging Trends in science
and technology. (2019)
Journal of Manufacturing
Processes, Volume 35 (2018)
The effect of interlayers on
carbon migration after aging
treatment (620 °C/500 h) was
evaluated with the help of
thermodynamic simulations
and it was observed that the
use of interlayers reduced the
severity of carbon migration.
The addition of activated flux
induce an inveraion of the
convection currents changing
the sign of the surface tension
gradient, resulting convection
movements changed to
centrifugal. Hence, the
penetration depth increase.
The joining of Inconel 600 and
AISI 316L plates using
compound flux of 50% SiO2 + 
50% TiO2 by (ATIG) welding
process has been addressed.
Xan Xie, Yangchuan Cai, xu Characterization of keyhole
Zhang, Zhen Luo gas tungsten arc welded AISI
430 steel and joint
performance optimization
Jun Shen Effects of cerium and SiC
Fuxing Xie mixed particles on
Huiyu Song nanoparticle strengthening
Xiong Xie activated TIG-welded AZ31
alloy joints
International journal Of The mechanical properties
Adavanced manufacturing and corrosion resistance of the
technology. (2018) enhanced joints improved.
the tensile properties of the
PWHT joint and the corrosion
resistance of the joint with the
austenite interlayer were
better than those of the base
metal.
Journal of Materials AZ31 magnesium alloy sheets
Research(2018) were A-TIG-welded through a
coating of flux, which
contained different ratios of
Ce powder and nano-sized SiC
as reinforcement particles and
equal mass of TiO2 as
activating fluxes.
Memduh Kurtulmu Activated Flux TIG Welding of
Austenitic Stainless Steels[2]
Guttikonda Raja kumar Effect of activated Flux and
nitrogen Addition On the bead
geometry Of boarted stainless
steel 304B gta welds[1]
Journal of Scientific and
Engineering Research, 2017,
4(7):169-177
MTAEC9, 50(3)357(2016)
INTERNATIONAL JOURNAL OF
ENGINEERING RESEARCH &
TECHNOLOGY (IJERT)
It is found that with this
process it is possible to
increase the weld penetration
and productivity up to three
times higher or more
compared to the TIG process.
Borated stainless steels (304B)
are used in nuclear power
plants as control rods, shielding
material, spent-fuel storage
racks and transportation casks
as they have a high capacity to
absorb thermal neutrons.
David Vijayanand Creep Deformation and
M. Vasudevan Rupture Behavior of Single-
V. Ganesan and Dual-Pass 316LN
Parameswaran Padmanabhan Stainless-Steel-Activated TIG
Weld Joints
Pandya, Dipali P. Experimental investigation on
duplex stainless steel weld by
Activated TIG welding and its
variants
Metallurgical and Materials
Transactions A 47(2016)
DEPARTMENT OF
MECHANICAL ENGINEERING
SCHOOL OF ENGINEERING
AND TECHNOLOGY
NAVRACHANA UNIVERSITY,
(2015)
Creep deformation and
rupture behavior of single-
pass and dual-pass 316LN
stainless steel (SS) weld joints
fabricated by an autogenous
activated tungsten inert gas
welding process have been
assessed by performing
metallography, hardness, and
conventional and impression
creep tests.
The effect of eight different
combinations (centre region
flux and
side region flux) of fluxes on
weld bead geometry is
analyzed. Furthermore, to
rationalize
Kuang- Huang Tseng Development and application
of oxide- based flux powder
for tungsten inert gas welding
of austenitic stainless steel
S. LATHABAI Joining of aluminium and its
alloys
Powder Technology
Elsevier(2013)
Woodhead publishing limited
(2011)
A satisfactory surface
appearance of the
stainless0.1steel activated TIG
weld was obtained with the
use of the discussed0.0novel
activated flux developed by
the NPUST.100 125 150 175
200 225 2502. For the
investigated currents of 125 to
.
There are two fundamental
approaches to joining a
material to another of similar
(or dissimilar) composition.
The principal difference
between the two approaches
is in the nature of the bond
created, which, in turn,
influences the nature of the
joint and its strength
 Research Gap
• In Conventional TIG Welding process Joining two dissimilar
metals is not possible due to - difference in there melting point,
limited dilution, poor deposition rate.
• And not getting the required depth of penetration on a single
pass thus directly influence the production.
• Edge/Groove preparation is the primary step to be done for
plates or pipe thickness 3mm or more which is obviously an
uneconomical and time killing step.

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Objective
• Joining two dissimilar metals copper and stainless steel with the use
of A- TIG welding.

• Investigation on Impact of different Flux on penetration.

• Analyzing the mechanical Properties of the weld.

• Analyzing microstructure of the weld.

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Experimental Design

Environmental Factor Current density

Moisture 125A
225A Mechanical
Room Temp properties&
microstructures
copper Sio2 of the weld joint
Stainless steel Tio2

Materials Types of Fluxes

Methodology 19
Literature
review • Patent search

• setup
Objective

Design of
experiments
• Layout
(Pattern
making)

• Availability
Experiment of • Compatibility
set up • Cost

Analyzing
Mechanical • Parameters
Properties and
microstructures.

Quality testing • List of table

of weld • Charts

Result and
discussion

Research paper
publication
 Work Plan
Work Plan July-August September-October November-December January-February March-April May-June

           
Literature reading

 
Objective

   
Experimental Setup
 

 
Experiment Design

Analyzing Mechanical strength ,    

And microstructures of weld

 
Quality testing of welded joint

 
Result and Discussion

 
Research paper publication

Current 20
Work plan
 References
• S.A afolalu ,O.M Ikumapayi -Investigation of mechanical properties and characterization of a joint using nano flux powder for a-tig welding
• S. Lathabai Joining of aluminium and its alloys
• Guttikonda Raja Kumar, Gabbita Durga Janaki Ram, Sajja Rama Koteswara Rao, effect of activated flux and nitrogen addition on the bead
geometry of borated stainless-steel gta welds, MTAEC9, 50(3)357(2016)
• Memduh Kurtulmu, Activated Flux TIG Welding of Austenitic Stainless Steels, Journal of Scientific and Engineering Research.
• Investigation of mechanical properties and characterization of a joint using nano flux powder for a-tig welding
• S.C. Bodkhe, D.R. Dolas, Optimization of activated tungsten inert gas welding of 304L austenitic stainless steel, Proc. Manuf. 20 (2018)
• N. Jeyaprakash, A. Haile, M. Arunprasath, The parameters and equipment used in TIG welding : a review, Int. J. Eng. Sci. 4 (2) (2015)
• https://www.researchgate.net/figure



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Thank You
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