Experimental investigations and Parametric optimisation of joining Copper and stainless steel by electron Beam welding for aerospace applications

Abstract

ABSTRACT newlineElectron Beam Welding (EBW) plays an important role in the aerospace industry where components like sensors, gears, actuators and air frames used in aircraft and rocket engines are welded using this technique. Welding is normally performed in a vacuum to avoid the scatter of electron due to the presence of gas molecules in the atmosphere and hence Electron beam welding process provides the greater results. But still joining of dissimilar metals is challenging. Industries such as aircraft manufacturing, nuclear power plants and oilreand#64257;nerieswitnessawiderangeofapplicationsindissimilarweldedjointsconsideringthe advantage of strength and high corrosion resistance. The primary objective of this research istostudythedissimilarmetaljointsofpureCopperandStainlessSteel304usingEBWfor Aerospace applications. Copper to Stainless Steel brazed segments are utilized as a part of the drive assembly ofcryogenicdrivearrangementofsemicryogenicrocketengines. Forhighheattransmission in theburningassemblyofcryogenicmotor, highconductivityCoppercompound isutilized for the internal shell to exchange the heat of ignition to the coolant liquid and furthermore to hold the quality and malleability at working conditions and Stainless Steel is utilized for theexternalshellforqualityandsimilarity. Joiningofthesedissimilarmetalshasconstantly represented an extraordinary test for material researchers. Joining of Copper with Stainless Steel is a complex process for researches due to the difference in physical, chemical and metallurgical properties of both metals. Joining of Copper is also not feasible by using existingweldingmethodsdueitshighthermalconductivityandsubsequentlyjoiningofthese dissimilar materials is more complex. EBW is a useful method in joining such dissimilar metal combinations. The heat generated by the electron beam melts the metals in different ratios because of the difference in the melting point of metals. The input parameters such as beam current, welding speed, work distance are responsible for a high quality weld.