Abstract
This study investigated the microstructure and mechanical properties of dissimilar vacuum electron beam welded joints between TU1 oxygen-free copper and 316L stainless steel. Sound, defect-free welds with a characteristic nail-head profile were achieved. The fusion zone exhibited a complex interpenetrating microstructure comprising Fe-rich and Cu-rich zones with dispersed particulates. EBSD analysis revealed a significant grain size gradient, with fine equiaxed grains at the fusion line and coarse columnar grains growing epitaxially into the fusion zone. Mechanical testing demonstrated that joint failure occurred in the weaker heat-affected zone rather than the weld joint, with a yield strength of ∼123.5 MPa and elongation of ∼6.8%. These results demonstrated that EBW was an effective technique for producing reliable copper/stainless steel dissimilar joints.
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