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Performance Evaluation of 70-30 Cu-Ni Filler Metal for Improving Dissimilar Al2024-SS304 Joints’ Efficiency: A Mechanical and Microstructural Investigation

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Abstract

This study aims to analyze the effect of 70-30 Cu-Ni filler metal on mechanical and microstructural properties of Al 2024 and stainless steel 304 hybrid joints fabricated through the gas tungsten arc welding technique. The mechanical properties, i.e., tensile strength and microhardness, of Al-SS joints have been analyzed and evaluated through joint interfacial microstructure analysis. The optimum tensile strength (155.746 MPa) has been obtained at welding current ranges between 75 and 80 A, welding speed of 110–115 mm/min, and gas flow rate of 9.75-10 L/min, whereas maximum microhardness (300 HV) at welding speed of 115-120 mm/min, welding current of 70-75 A, and gas flow rate of 9.5-10 L/min. The fine equiaxed dendrites at the interface of the aluminum weld zone and the thin interfacial layer at the SS304 weld zone interface contributed to the higher tensile strength. Scanning electron microscopy, energy-dispersive spectroscopy, and x-ray diffraction reveal the ductile CuAl, NiAl3, and NiAl phases instead of Fe-Al brittle phase, improving hybrid bonding between Al 2024 and SS 304. The dimples and tear ridges microstructure have been observed for high-strength joint, while cracks and cavities on the fracture surface indicate its brittleness and low strength (102 MPa).

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Authors and Affiliations

  1. Department of Industrial Engineering, University of Engineering and Technology, Taxila, 47080, Pakistan

    Muhammad Jawad, Asad Ali, Mirza Jahanzaib & Muhammad Sajid

  2. Department of Industrial and Manufacturing Engineering, University of Engineering and Technology, Lahore, 54890, Pakistan

    Kashif Ishfaq

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Contributions

Research idea and design by [MJ] and [AA], materials preparation, experimentation by [MJ], and [AA], data analysis and testing [MJ], and [MS], first draft of writing by [MJ], [KI] and [MJ], reviewing process by [KI] and [MJ], guidance and supervision by [MJ].

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Correspondence to Muhammad Jawad.

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Jawad, M., Ali, A., Ishfaq, K. et al. Performance Evaluation of 70-30 Cu-Ni Filler Metal for Improving Dissimilar Al2024-SS304 Joints’ Efficiency: A Mechanical and Microstructural Investigation. J. of Materi Eng and Perform (2023). https://doi.org/10.1007/s11665-023-08659-x

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