Characterization of Dissimilar Alloys Welding Techniques with Enhanced Galvanic Corrosion

3 Abstract: In recent era, requirement for joining dissimilar alloys is increasing gradually. A lot of benefits are acquired by welding dissimilar alloys. Better and hybrid properties can be obtained with reduced overall cost. In present research work, sheets of AISI 304 which is an austenitic stainless steel and AISI 1040 that is a medium carbon steel were joined together by using Shielded Metal Arc Welding (SMAW) and Gas Tungsten Arc Welding (GTAW) techniques. The welding joint was completed in three passes by using E-309 16 and ER-309 L welding electrodes for SMAW and GTAW respectively. Standard samples were prepared for Tensile test, Impact test, Bend test, Hardness test and Metallography from welded sheets. SMAW and GTAW joints were characterized by means of Mechanical Testing and microstructure was analyzed under Scanning Electron Microscope (SEM). It was concluded that GTAW joints possess superior qualities as compared to the SMAW joints. However, it was observed that sheet of AISI 1040 got corroded. To avoid corrosion, the welded sheets were coated by electrolytic cadmium plating. The cadmium plated samples were then tested for accelerated corrosion testing in Salt Spray Chamber for 96 hours according to the standard ASTM B117. Solution of 5 % NaCl was utilized in the Fog Test. After 96 hours no corrosion of any type was detected. Thus it is proved that GTAW welded AISI 1040 and AISI 304 materials with cadmium plating can provide optimized results and can be sued for different engineering applications.