Experimental Investigations and Parametric Optimisation of Joining Copper and Stainless Steel by Electron Beam Welding for Aerospace Applications
DOI:
https://doi.org/10.15662/IJEETR.2026.0802290Keywords:
Electron Beam Welding, Copper–Stainless Steel Joining, Aerospace Applications, Weld Microstructure, Mechanical Properties, Heat Input OptimizationAbstract
The demand for lightweight, high-performance, and thermally efficient materials in aerospace applications has led to increased interest in dissimilar metal joining, particularly copper and stainless steel. However, the significant differences in their thermal and physical properties present major challenges during welding. This study investigates the feasibility of joining copper and stainless steel using Electron Beam Welding (EBW) and focuses on the experimental evaluation and parametric optimisation of the process. Key welding parameters such as beam current, welding speed, beam offset, and beam power are analyzed to understand their influence on weld quality, microstructure, and mechanical properties. Experimental results demonstrate that EBW produces high-quality joints with minimal heat-affected zones and reduced distortion. Optimal parameter settings significantly improve tensile strength, hardness, and microstructural uniformity. The study confirms that EBW is a suitable and reliable technique for aerospace-grade dissimilar metal joining.
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