International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 13 Issue: 08 | Aug 2026
p-ISSN: 2395-0072
www.irjet.net
ER309L-Filled Dissimilar GTAW Joints between AISI 304 Stainless Steel and AISI 1010 Low-Carbon Steel Philip Baidoo1, Banabas N. Bediako1, Emmanuel Obobi Tettefio2 and Vivian Hinneh3 1Department of Mechanical and Automotive Technology Education, University of Skills Training and Entrepreneurship
Development, Kumasi, Ghana
2Department of Mechanical Engineering, Ho Technical University, Ho, Ghana
3Department of Engineering, Mampong Technical College of Education, Mampong, Ghana
------------------------------------------------------------------***--------------------------------------------------------------Abstract-Since ancient times, welding technology has engaged in recreation a noteworthy protagonist in metal joining processes. This study investigated the effects of using a transitional filler material, ER309L, to join AISI 304 austenitic stainless steel and AISI 1010 low carbon steel (LCS) using Gas Tungsten Arc Welding (GTAW). The study aimed to evaluate the mechanical properties and microstructure of the welded joints. Weldment joints stood prepared using three filler materials, and their tensile properties, impact strength, hardness values and microstructures were determined. The TIG welding process uses a nonconsumable tungsten electrode to generate the weld, which is protected from oxidation and contamination by an inert gas shield. The results revealed welds that were free from impurities and had a clean, high-quality appearance. The use of ER309L as a transitional filler material for joining AISI 304 austenitic stainless steel (ASS) and AISI 1010 low carbon steel positively influenced the mechanical and microstructural properties of the weldment, making it suitable for high-quality weld production in industries such as aerospace and automotive engineering. Keywords: TIG Welding; transitional filler martial; Extensometer gauge length; material exhibits; Yield strength; Shielding Gas. Weldment has been started since ancient times. Humphry Davy discovered the electric arc by using a battery and two carbon electrodes. However, this has principles of gas metal arc weldment were developed after the invention of the electric generator [1]. The gas metal arc welding process is widely used nowadays in automobiles, railway construction, ship buildings, and nuclear power plants Metal can be transferred to the weld pool in three ways, such as globular type, short circuit type, and spray type. Pulsed spray metal transfer was introduced after as a modification of the spray metal transfer mode. Spray metal transfer was the first mode used in this process. Each type of metal transfer has its own influential with regards of usage, required arc current and weld penetration [2]. In dissimilar metal welding, filler metal plays an important role because its composition often differs from that of the parent metals. During welding, the parent metals and filler metal combine in a specific ratio to form the weld metal. Therefore, controlling the composition of the weld metal is essential when joining dissimilar metals. The weld metal composition can be determined based on the assumption that it is formed from a mixture of the parent metals and the filler metal [3]. In modern steel construction, it is sometimes necessary to produce durable dissimilar metal joints between low-alloy or carbon steel and stainless steel [4]. The automobile industry, pressure vessels and shipbuilding. The formation of intermetallic compounds makes the joining of dissimilar materials more difficult. During dissimilar metal welding, key factors such as weld metal, composition, dilution, melting temperature, thermal conductivity, and coefficient of thermal expansion, may lead to weld discontinuities [5]. The researchers intended to investigated Influence of ER309L filler Materials in Joining AISI304 ASS and AISI1010 LCS by using GTAW, also known as TIG welding. When a structure fails due to the loss of mechanical properties of weld metal, the financial and endangering losses and risk of human life can be significant. Therefore, it is critical to find ways to improving the durability and reliability of welded joints [6]. Poor weld characteristics and fatigue failure remain among the most common causes of welded structural failure in construction and mining equipment, railways, ships, agricultural machinery, bridges, and off-shore equipment, resulting in significant economic losses. During operation, structural members and components in these structures are constantly subjected to variable-amplitude loading, [7]. Dissimilar joint of low-alloy ferritic steel and austenitic stainless steel have been widely used in many industries. [8] studied the joining of A240 TP316 austenitic stainless steel and A387 Gr.11 low-alloy ferritic steel using the GTAW process with constant and pulsed currents. Two types of filler metals namely, ER309L and ERNiCr-3, were used in this investigation. The
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