Asi304& Mild Steel

TIG WELDING OF AISI 304 STAINLESS STEEL WITH
MILD STEEL: EXPERIMENTAL INVESTIGATION
PRESENTED BY
NAME MAKUT ROLL NO.
AKASH NANDI 10900714005
ARIK MITRA 10900714013
ARKO ROY 10900714016
ARNAB BHATTACHARYA 10900714017
PURNAYU SARKAR 10900714069
ACKNOWLEDGEMENT
WE HEREBY ACKNOWLEDGE OUR GRATEFULNESS TO MR.PRADEEP KUMAR

PAL, NETAJI SUBHASH ENGINEERING COLLEGE, AND MR.ABHISHEK
GHOSH,SUPREMO COLLEGE MANKUNDU FOR THEIR INVALUABLE
GUIDANCE AND INSIGHT IN BRINGING THIS PROJECT TO FRUITON.THEY
HAVE OUR HEARTFELT GRATITUDE.
INTRODUCTION
PART 1
 Welding is one of the most commonly used fabrication techniques for

manufacturing engineering components for different sectors. Welding is a
process of joining metallic or other components with or without
application of heat, with or without pressure; with or without filler metal
in which coalescence of the joining materials/components occur.
 Welding differs from other joining processes in that the joint created by
welding is very strong and permanent. Parts that have been welded
together cannot be easily separated. Though there are many welding
processes, arc welding is still the most popular welding process.
PROJECT AIM
 In this present work we have studied the dissimilar welding of Austenitic

Stainless Steel (AISI 304) and Mild Steel. The welding that has been
performed is TIG welding . After having performed the welding operation
it is our intention to study the properties of the weld. This study will
include tests for Tensile Strength , Microstructure and Optimisation of the
welding parameters.
 The applications and advantages of dissimilar welding will also be looked
into at length.
STAINLESS STEEL WELDING
• Stainless steel is not a single material, but a family of different types

and grades, based on alloying chromium (Cr) with iron (Fe). The details
of the various classifications, grades and their properties and
corrosion resistance have been covered in previous modules of this series.
• In welding there are three zones of principal concern:
1. The solidified weld metal, composed of either base metal or filler metal.
2. The Heat Affected Zone (HAZ) in which the base metal is heated to high
temperatures but less than the melting temperature.
3. The base metal which is only moderately warmed or not warmed at all.
AUSTENITIC STAINLESS STEEL
• Austenitic Stainless steels containing
Chromium and Nickels are the principal
alloying elements (in addition to Iron) are
identified as AISI 300 series type. Those
containing Chromium, Nickel and
Manganese (in addition to Iron) are
identified as AISI 200 series types.
• Resistance to corrosion is their principal
attribute but they are also selected for
their excellent strength properties at high
or extremely low temperatures.
• The melting point of the austenitic grades
is lower, so less heat is required to
produce fusion. Their electrical resistance
is higher than that of mild steel so less
electrical current (lower heat settings) is
required for welding.
Mild Steel
• Mild Steel is the most widely

used steel which is not brittle
and cheap in price. Mild steel is
not readily tempered or
hardened but possesses enough
strength. Mild steel contains –
• Carbon 0.16 to 0.18%
(maximum 0.25% is allowable),
Manganese 0.70 to 0.90%,
Silicon Maximum 0.40%,
Sulphur maximum 0.04% and
Phosphorous maximum 0.04%.
These tests need to be done for study the
dissimilar welding .
• Visual Inspection
• Tensile test
• Hardness Test
• Toughness test
• Fatigue Test
• Microstructure study
WELDING
• Welding as it is normally understood

today is comparatively a new comer
amongst the fabrication processes. It is
a process of joining two or more parts
of material. Though it provides a
permanent joint, it does normally
affect the metallurgy of the
components. It is, therefore, usually
accompanied by post weld treatment
for most of the critical components.
Most of the welding processes utilize
heat and or pressure for making a weld
joint.
DISSIMILAR WELDING
• Another method of joining dissimilar metals
is the use of a composite insert between the
two metals at the weld joint. The composite
insert consists of a transition joint
between dissimilar metals made by a
welding process that does not involve
heating.
CLASSIFICATION OF WELDING PROCESS
HISTORY OF TIG WELDING
• The Gas Tungsten Arc Welding (GTAW) process is sometimes referred to as
TIG. TIG is short for Tungsten Inert Gas Welding. The aircraft industry
developed the GTAW process for welding magnesium during the late
1930’s and 1940’s.During that time, helium was the primary shielding gas
used, along with DCEP welding current. These caused many problems that
limited application of GTAW welding process. But improve the process
effectiveness and reduced its cost. Before the development of the GTAW
process, welding aluminium and magnesium was difficult. The weld
produced was porous and corrosion prone.
TUNGSTEN INERT GAS WELDING
• In the present study, TIG welding is used. Some aspects of TIG welding are
discussed here.
• TIG welding is often used to join high strength reactive metals and alloys
such as stainless steel, aluminium and magnesium alloys. Tungsten inert
gas welding uses a electrode primarily made of tungsten and an inert gas
for shielding the weld pool contamination from atmospheric gases. When
inert gas is used as shielding gas, this process is also called gas tungsten
arc welding (GTAW). Invention of this process in mid of twentieth century
gave a big boost to fabrication of these reactive metals. Despite of so
many developments in the field of welding, TIG welding is still
recommended for joining of thin aluminium sheet of thickness less than 1
mm .
SAFETY TIPS FOR TIG WELDING
• Dry hole free insulating gloves

and body protection.
• Approved safety glasses with side
shields under your helmet.
• Protective clothing made from
durable, flame resistance (leather
,heavy cotton)and foot protection
ADVANTAGES OF TIG WELDING
• It has the ability to join a wide range of material types and thicknesses.
• Equipment used in TIG welding process is simple, having the capability of all-
position welding.
• TIG welding has higher electrode efficiencies, usually between 93% and 98%,
when compared to other welding processes.
• TIG welding can be easily adapted for high-speed robotic, hard automation
and semiautomatic welding applications.
• Excellent weld bead appearance, minimum of weld spatter and slag, makes
the weld clean up fast and easy.
• GTAW provides lower heat input when compared to other welding processes.
• Lower cost is required per length of weld metal deposited compared to other
arc welding processes. Cost of the electrode is not high.
LIMITATIONS OF TIG WELDING
• The higher heat input in TIG welding, generally restricts its use to thicker
base materials.
• The higher heat input mode of TIG welding is restricted to flat or
horizontal welding positions only.
• The use of argon based shielding gas is more expensive than 100% carbon
dioxide (CO2).
WELDING DEFECTS -1
• Welding defects can greatly affect weld performances and longevity.
According to ASME, cause of welding defects are broken down as follows:
45% poor process conditions, 32% operator error, 12% wrong technique,
8% incorrect consumables, 3% bad weld grooves. General welding defects
are given below:
• Overlap: It is caused by poor welding techniques and can generally be
overcome by an improved weld procedure. The overlap can be repaired by
grinding off excess weld metal and surface grinding to the base metal
• Undercut: It is an unfilled groove along the edge of the weld. The causes
are usually associated with incorrect electrode angle, excessive current
and travel speed. Undercutting can be avoided with careful attention
during preparation of the edge and by improving the welding process.
WELDING DEFECTS 2
 Cracking: Cracks and planar discontinuities are some of the most

dangerous, especially if they are subjected to fatigue loading condition.
Longitudinal cracks run along the direction of the weld and are usually
caused by a weld metal hardness problem. Cold cracking occurs after the
welding when metals are completely solidified.
 Lamellar tearing : Lamellar tearing is a type of defect that is most likely

to occur below a welded joint at points of high stress concentration. It is
created by non-metallic inclusion being rolled into the hot plate metal
during fabrication. Special joint design minimizes this defect.
WELDING DEFECTS 3
• Porosity :Cavities or pores caused by gas and non-metallic material

entrapment in molten metal during solidification are called porosity.
There are many causes which include contamination, inadequate
shielding, too short arc gap and poor welding technique. Porosity can be
minimized by proper selection of electrode, filler material and slower
speed to allow time for gasses to escape.
• Incomplete fusion: It occurs when the weld metal does not form a
cohesive bond with the base metal or when the weld metal does not
extend into the base metal to the required depth. This type of defects
occurs due to low current, insufficient preheating, too fast welding speed,
incorrect edge preparation, arc not being at the centre to the seam.
Porosity defect
Incomplete fusion defect
Spatter
• Spatter: occurs from

metal drops expel
surrounding surfaces.
Spatter can be
minimized by correcting
the welding condition
and should be
eliminated by grinding
when present .
WELDING DEFECTS 4
• Inclusions: Inclusions are generated by extraneous material such as slag,

tungsten, sulphide and oxide inclusion. Slag inclusion not only reduces
cross sectional area and thus strength of the joint but also serves as
initiation point for serious cracking. This defect can be eliminated by
grinding down or re-welding.
Future Scope of Work
• In the present study TIG welding of AISI 304 stainless steel with mild steel has been
considered. In future, experiments and analyses may be carried out in respect of GMAW
of AISI 304 stainless steel with AISI 420 stainless steel, as well . Experiments may be
planned for TIG welding of some other austenitic stainless steel grades like 304, 316,
316L, 316LN etc. with other martens tic stainless steel grades like 403, 410H, 420HC etc.
• The effects of voltage, filler wire diameter and composition of filler wire may be studied
through experiments and analysis.
• Effect of process parameters with variation in edge preparation may also be studied in
respect of TIG welding of austenitic stainless steel with martensitic stainless steel, with
larger thickness.
Change in weld bead geometry with change in process parameters can also be studied.
• Techniques of optimization like Gray-Taguchi method, principal component analysis,
ETLBO, ant colony optimization etc. may be used in future work for optimization of the
responses, and for establishing relative usefulness of these different techniques.
THANK YOU

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TIG WELDING OF AISI 304 STAINLESS STEEL WITH

MILD STEEL: EXPERIMENTAL INVESTIGATION

WE HEREBY ACKNOWLEDGE OUR GRATEFULNESS TO MR.PRADEEP KUMAR

 Welding is one of the most commonly used fabrication techniques for

 In this present work we have studied the dissimilar welding of Austenitic

• Stainless steel is not a single material, but a family of different types

• In welding there are three zones of principal concern:

• Mild Steel is the most widely

• Welding as it is normally understood

• Dry hole free insulating gloves

 Cracking: Cracks and planar discontinuities are some of the most

 Lamellar tearing : Lamellar tearing is a type of defect that is most likely

• Porosity :Cavities or pores caused by gas and non-metallic material

• Spatter: occurs from

• Inclusions: Inclusions are generated by extraneous material such as slag,

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