Analysis of Mechanical and Microstructural properties of Electron Beam Welded dissimilar Ferrous alloys

Analysis of Mechanical and Microstructural properties of Electron Beam Welded dissimilar Ferrous alloys | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Analysis of Mechanical and Microstructural properties of Electron Beam Welded dissimilar Ferrous alloys Shailendra Singh, Rajnish Singh This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-4537546/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract Electron Beam Welding (EBW) is an important welding process in the present scenario. It is applied to various fields, including the fabrication of difficult-to-weld materials in the engineering, aerospace, and automobile industries. It can weld similar and dissimilar material with fine Heat-affected zones and produces high-strength joints. The joining of dissimilar materials becomes very easy through the EBW route. The EBW welded samples achieved a high depth-to-width ratio & focused accurately on the area to be welded. Therefore, it minimizes the area of the heat-affected zone (HAZ). In this work, the study focused on optimizing the process parameters of EBW welding parameters like current, voltage, welding speed for strength, and hardness of weld bead. The materials selected were mild steel and EN8. A Taguchi technique-based experiment has been used to find the data. Then, welding parameters are optimized to get optimum strength, hardness on the weld bead, and hardness on the heat-affected zone of the welded joint. The Optimized tensile strength was 600MPa, at Voltage = 50KV, Beam Current = 4 mA, and welding speed = 75 mm/min. The weld bead hardness was 146.4 HV, at Voltage = 50KV, Beam Current = 4 mA, and welding speed = 75 mm/min at optimized conditions. The Optimized hardness on HAZ is 163.23 HV on EN-8 & 160.43 HV on Mild steel at Voltage = 45KV, Beam Current = 4 mA, and welding speed = 50 mm/min. HAZ EBW Microhardness Taguchi Optimization Full Text Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-4537546","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":319784976,"identity":"c0d7fa73-f5c1-4daa-b6a4-33658d7cd713","order_by":0,"name":"Shailendra Singh","email":"","orcid":"","institution":"Kamla Nehru Institute of Technology","correspondingAuthor":false,"prefix":"","firstName":"Shailendra","middleName":"","lastName":"Singh","suffix":""},{"id":319784977,"identity":"a9b4ff14-be21-4ea2-9c50-eb09e5cd97b3","order_by":1,"name":"Rajnish Singh","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAABDUlEQVRIiWNgGAWjYHCCBCA8wMDADEIVCQxsEFEJYrWcAWphI6wFBA6ASWbGtgQGmDU4gXn7gWcPHvy5wyDfznv4deG8tDw++QbGDz8YLPJwaZE5k5BukNj2jMHgMF+a9cxtOcVAhzFL9jBIFOPSIsGQkCaR2HCYwYCZx8yYd1tFYhvQYdJAicQGXFr4H6RJJPw5zCDfDNIyB6yF+TdeLRJAWxLYDjMwHOYxfszbkAPSwobfFgmgLYlth3kMDvOYMfMcSwNqSWyz7DHA57CcNMkffw7LyfefMf7MU5OcOL/58OEbPyrqcGphYOBJAJNAzAaNPkagYgOc6oGA/QCMxfwBn7pRMApGwSgYuQAAFgpOLZicRqAAAAAASUVORK5CYII=","orcid":"https://orcid.org/0000-0002-0642-2509","institution":"Kamla Nehru Institute of Technology","correspondingAuthor":true,"prefix":"","firstName":"Rajnish","middleName":"","lastName":"Singh","suffix":""}],"badges":[],"createdAt":"2024-06-06 05:49:27","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-4537546/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-4537546/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":81211281,"identity":"3b2061aa-9a97-400d-83f0-d73cc7c3fad3","added_by":"auto","created_at":"2025-04-23 13:24:11","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1642168,"visible":true,"origin":"","legend":"","description":"","filename":"EBWPaper.pdf","url":"https://assets-eu.researchsquare.com/files/rs-4537546/v1_covered_fe44501f-6157-4074-9c0f-f549fe728b8c.pdf"}],"financialInterests":"","formattedTitle":"Analysis of Mechanical and Microstructural properties of Electron Beam Welded dissimilar Ferrous alloys","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"HAZ, EBW, Microhardness, Taguchi, Optimization","lastPublishedDoi":"10.21203/rs.3.rs-4537546/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-4537546/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eElectron Beam Welding (EBW) is an important welding process in the present scenario. It is applied to various fields, including the fabrication of difficult-to-weld materials in the engineering, aerospace, and automobile industries. It can weld similar and dissimilar material with fine Heat-affected zones and produces high-strength joints. The joining of dissimilar materials becomes very easy through the EBW route. The EBW welded samples achieved a high depth-to-width ratio \u0026amp; focused accurately on the area to be welded. Therefore, it minimizes the area of the heat-affected zone (HAZ). In this work, the study focused on optimizing the process parameters of EBW welding parameters like current, voltage, welding speed for strength, and hardness of weld bead. The materials selected were mild steel and EN8. A Taguchi technique-based experiment has been used to find the data. Then, welding parameters are optimized to get optimum strength, hardness on the weld bead, and hardness on the heat-affected zone of the welded joint. The Optimized tensile strength was 600MPa, at Voltage\u0026thinsp;=\u0026thinsp;50KV, Beam Current\u0026thinsp;=\u0026thinsp;4 mA, and welding speed\u0026thinsp;=\u0026thinsp;75 mm/min. The weld bead hardness was 146.4 HV, at Voltage\u0026thinsp;=\u0026thinsp;50KV, Beam Current\u0026thinsp;=\u0026thinsp;4 mA, and welding speed\u0026thinsp;=\u0026thinsp;75 mm/min at optimized conditions. The Optimized hardness on HAZ is 163.23 HV on EN-8 \u0026amp; 160.43 HV on Mild steel at Voltage\u0026thinsp;=\u0026thinsp;45KV, Beam Current\u0026thinsp;=\u0026thinsp;4 mA, and welding speed\u0026thinsp;=\u0026thinsp;50 mm/min.\u003c/p\u003e","manuscriptTitle":"Analysis of Mechanical and Microstructural properties of Electron Beam Welded dissimilar Ferrous alloys","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2024-07-19 07:35:55","doi":"10.21203/rs.3.rs-4537546/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"976b94e8-e448-4fea-830e-e3d25885e72e","owner":[],"postedDate":"July 19th, 2024","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[],"tags":[],"updatedAt":"2025-04-23T13:23:34+00:00","versionOfRecord":[],"versionCreatedAt":"2024-07-19 07:35:55","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-4537546","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-4537546","identity":"rs-4537546","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}