Welding is a joining technique that involves melting a portion of separate metal pieces, so they fuse at a particular location. When working with pieces of the same type of metal, creating a solid join is a relatively straightforward process, since all the parts will react the same way to heat. However, if they're different from one another, you'll need to do more planning.

An Introduction to Dissimilar Welding

Feasibility

Although it's not impossible, dissimilar welding is challenging. Part of the problem lies in the difference in melting points. For example, copper begins to melt when it reaches 1981 °F, whereas stainless steel starts to melt around 2550 °F. To overcome this discrepancy, a welder might use a filler metal between the two pieces. Also known as a "welding consumable," this material acts as a buffer, absorbing the heat for the metal with the lower melting point.

Additional Worries

The melting point isn't the only concern. A metal's thermal conductivity, or its heating and cooling rate, must also be considered. Additionally, you can't begin without understanding the coefficients of thermal expansion—how much they grow or shrink in different temperatures. If the differences between these properties are too large, the finished product will be misshapen.

Possible Problems

Aside from a distorted product, another problem to account for with dissimilar welding is tensile strength. The durability of the final welded piece will only be as strong as the weaker metal. Failure to account for this can result in poor structural integrity and cracking. To reduce the likelihood of this happening, you must take these differences into account and offset them by pre-heating the pieces or using filler metal.

Whether you have a brand new welding project or you need a few repairs, turn to Incom. Located in Kailua Kona, HI, they have more than 40 years of experience in the industry. Their welders are also certified by the American Welding Society, so you can trust the quality, strength, and longevity of their work. For more information about their services, visit their website. To get a free estimate, call (808) 329-1311.