A novel approach to optimize weld formation and regulate interfacial microstructure in TC4/304SS dissimilar arc welding by active hybrid shielding gas

CO2 shielding gas was innovatively employed for TC4/304SS dissimilar metal arc welding, overcoming the limitation of active gas application for Ti welding. The effect of CO2 addition on welding process was investigated. Our results show that the CO2+Ar hybrid shielding gas eliminated the problem of insufficient bonding at the backside of the steel plate, and was helpful to obtain a full weld joint. Moreover, the microstructure of the weld joint was modified due to the intense mass transfer inside the molten pool. The typical Ti/Cu interface was divided into two layers. No Ti–Fe compounds were found within the Ti/Cu interface for pure Ar shielding gas. However, the interface morphology was found to change due to induced CO2. Some TiFe2+Ti5Si3 dendrites were formed in layer Ⅱ. And the TEM results showed that the addition of CO2 did not contribute to the generation of a new phase, but the island-shaped Ti2Cu3 was transformed to a lath shape. In the weld seam center, Ti–Fe–Si ternary compounds was formed instead of Ti–Fe or Ti–Cu compounds. The hardness of the entire joint increased with increasing CO2 content. An average strength of 480 MPa was obtained for 3% CO2 content, which is an increase of 57.9% compared to that for pure Ar shielding condition. The fracture surface morphology showed small cleavage flatforms with some shallow dimples. Better weld formation and the optimization of the interface microstructure both contributed significantly to the improvement of the tensile strength of the Ti/steel joint.