Electron Beam Welding of Mild Steel to Oxygen Free Copper

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In electron beam welding, the greatest advantage is the possibility of welding all kinds of dissimilar metals with a high energy density electron beam (about one hundred thousand times as large as energy density in arc-welding). Authors now studying the weldability of various combinations of dissimilar metals by electron beam have found some interesting phenomena in the joints of these metals, such as microstructure of weld zone, which could not be found in the conventional welding method. A dissimilar joint of mild steel to oxygen-free copper reported here shows these typical phenomena. The difference in physical properties between these two metals results in a different penetration behavior in electron beam welding, and this penetration behavior causes difficulties even with this excellent welding method. The purpose of this research program is to produce a sound dissimilar weld joint. This report is part of that program, and deals with the following items ; relation between welding condition and penetration depth or width, effects of beam spot on penetration shape, effects of aluminum addition on the microstructure of weld zone and on mechanical properties of the joint (addition of aluminum is intended to improve weldability, since aluminum bronze, Cu-7 to 12% Al, is used in these dissimilar metal joints as filler metal by TIG welding), and furthermore, effects of nickel and monel (70% Ni-30% Cu)-insert-metal on the microstructure of the weld zone and on mechanical properties of the joint (insert of nickel is intended to improve weldability, since nickel is fully soluble to Fe and Cu). The conclusions are : 1) In the electron beam welding of mild steel to oxygen-free copper, addition of aluminum is found effective in yielding sound dissimilar metal joints (i.e. the joints exhibited same tensile strength as copper base metal, low hardness at weld zone, stable microstructure), but high hardness of weld zone cannot be avoided in the case of too much additional aluminum. 2) Nickel and monel inserts also effectively produce sound dissimilar metal joints. 3) Mechanical strength in bending tests of the dissimilar metal joints is not improved by adding aluminum or using nickel or monel insert ; this important problem remains to be solved.
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Electron Beam Welding of Mild Steel to Oxygen Free Copper

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