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Microstructure and mechanical properties of dissimilar ferritic (S355)–austenitic (AISI 304) steel joints welded by robotic GMAW

  • Ozan Çoban

    Asst. Prof. Dr. Ozan Çoban, born in 1989, graduated with a PhD degree (2023) in Metallurgical & Materials Engineering from Istanbul Technical University, Türkiye. He is currently working as an academic member of Istanbul Gedik University, as the head of Welding Technology Program and director of Istanbul Gedik University Welding Technology Application and Research Center, also lecturing in Engineering Faculty. His main research areas are welding metallurgy, extractive metallurgy, and synthesis of nanoparticles of advanced ceramics. Currently, he has been focusing on wire arc additive manufacturing.

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Published/Copyright: April 14, 2025
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Materials Testing
From the journal Materials Testing Volume 67 Issue 5

Abstract

In applications requiring high corrosion resistance, it is crucial to utilize dissimilar welding techniques that incorporate structural steels in critical areas to reduce costs, rather than constructing the entire structure from high-cost stainless steels. Ferritic steels are often preferred due to their higher strength compared to stainless steels. In this study, Gas Metal Arc Welding (GMAW) was performed on 12 mm thick S355 structural steel and AISI 304 austenitic stainless steel using SG307 austenitic filler metal. Following welding operations with three different heat inputs, macrostructural assessments were carried out according to the EN ISO5817:2023(E) standard on the welds deemed successful based on nondestructive tests. Microstructural characterization, microhardness tests, tensile test, and impact tests (performed by notching different regions of the weld joint) were also conducted. The results demonstrated that undesirable changes in mechanical properties due to microstructural transformations in the welding of carbon steels with austenitic stainless steels can be mitigated with the correct parameters and proper filler metal selection. Thus, the mechanical properties required to ensure the expected performance of the welded structure were successfully achieved. Results revealed that the dissimilar joint efficiency with respect to yield strength of ferritic steel was calculated as 103.77 % and 175.42 % for austenitic AISI 304 steel. The impact toughness test results for the heat-affected zone (HAZ) of S355 steel showed satisfactory levels. Although the dissimilar weld metal region exhibited lower toughness values, they remained above 100 J.

Keywords: austenitic steel; carbon steel; characterization; dissimilar weld; ferritic steel; mild steel
Corresponding author: Ozan Çoban, Gedik Vocational School, Machinery and Metal Technologies Department, Welding Technology Program, Istanbul Gedik University, 34913, Istanbul, Türkiye; and Welding Technology Application and Research Center, Istanbul Gedik University, 34913, Istanbul, Türkiye, E-mail:

About the author

Ozan Çoban

Asst. Prof. Dr. Ozan Çoban, born in 1989, graduated with a PhD degree (2023) in Metallurgical & Materials Engineering from Istanbul Technical University, Türkiye. He is currently working as an academic member of Istanbul Gedik University, as the head of Welding Technology Program and director of Istanbul Gedik University Welding Technology Application and Research Center, also lecturing in Engineering Faculty. His main research areas are welding metallurgy, extractive metallurgy, and synthesis of nanoparticles of advanced ceramics. Currently, he has been focusing on wire arc additive manufacturing.

Acknowledgments

Author wishes to thank Prof. Dr. Mustafa Koçak, Gedik Welding Inc. and Istanbul Gedik University Welding Technology Application and Research Center for their support.

  1. Research ethics: Not applicable.

  2. Informed consent: Not applicable.

  3. Author contributions: The author has accepted responsibility for the entire content of this manuscript and approved its submission.

  4. Use of Large Language Models, AI and Machine Learning Tools: None declared.

  5. Conflict of interests: The author states no conflicts of interest.

  6. Research funding: None declared.

  7. Data availability: Not applicable.

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Supplementary Material

This article contains supplementary material (https://doi.org/10.1515/mt-2024-0405).

Published Online: 2025-04-14
Published in Print: 2025-05-26

© 2025 Walter de Gruyter GmbH, Berlin/Boston

Articles in the same Issue

  1. Frontmatter
  2. Review on three-point bending test for evaluating the mechanical properties, fracture behavior, and adhesion strength of coating/substrate systems
  3. Gas metal arc weldability of a Strenx 700MC-AISI304 dissimilar joint
  4. Effect of process parameters on mechanical properties of 5554 aluminum alloy fabricated by wire arc additive manufacturing
  5. Coating of TIG-welded micro-alloyed 38MnVS6 steel with flux-cored wire and FeB addition: microstructure, hardness, and wear properties
  6. Manufacturing parameters’ effects on the flexural properties of 3D-printed PLA
  7. Modified hot-spot stress method for fatigue life estimation of welded components
  8. Water as blowing agent in polyurethane resins creating porous cancellous bone surrogates for biomechanical osteosynthesis applications
  9. Enhancing cervical spine health: a vibration-focused multibody dynamics model for neck support system design
  10. Characterization of novel fibers extracted from Rumex obtusifolius L. plant for potential composite applications
  11. Interface metallurgical characteristics of dissimilar friction welded steels
  12. Effect of atmospheric pressure plasma treatment on the wettability and aging behavior of metal surfaces
  13. Microstructure and mechanical properties of dissimilar ferritic (S355)–austenitic (AISI 304) steel joints welded by robotic GMAW
  14. Enhanced Greylag Goose optimizer for solving constrained engineering design problems
  15. Effect of sustainable cooling and lubrication method on the hole quality and machinability performance in drilling of AA7075 alloy with cryogenically treated carbide drills
  16. Design optimization of a connecting rod for energy savings
https://doi.org/10.1515/mt-2024-0405
Keywords for this article
austenitic steel; carbon steel; characterization; dissimilar weld; ferritic steel; mild steel

Articles in the same Issue

  1. Frontmatter
  2. Review on three-point bending test for evaluating the mechanical properties, fracture behavior, and adhesion strength of coating/substrate systems
  3. Gas metal arc weldability of a Strenx 700MC-AISI304 dissimilar joint
  4. Effect of process parameters on mechanical properties of 5554 aluminum alloy fabricated by wire arc additive manufacturing
  5. Coating of TIG-welded micro-alloyed 38MnVS6 steel with flux-cored wire and FeB addition: microstructure, hardness, and wear properties
  6. Manufacturing parameters’ effects on the flexural properties of 3D-printed PLA
  7. Modified hot-spot stress method for fatigue life estimation of welded components
  8. Water as blowing agent in polyurethane resins creating porous cancellous bone surrogates for biomechanical osteosynthesis applications
  9. Enhancing cervical spine health: a vibration-focused multibody dynamics model for neck support system design
  10. Characterization of novel fibers extracted from Rumex obtusifolius L. plant for potential composite applications
  11. Interface metallurgical characteristics of dissimilar friction welded steels
  12. Effect of atmospheric pressure plasma treatment on the wettability and aging behavior of metal surfaces
  13. Microstructure and mechanical properties of dissimilar ferritic (S355)–austenitic (AISI 304) steel joints welded by robotic GMAW
  14. Enhanced Greylag Goose optimizer for solving constrained engineering design problems
  15. Effect of sustainable cooling and lubrication method on the hole quality and machinability performance in drilling of AA7075 alloy with cryogenically treated carbide drills
  16. Design optimization of a connecting rod for energy savings
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