On the Chemical Composition and Shear Strength of Electron Beam Welded Cu-ETP and AISI304 Dissimilar Metals Using a Statistical Approach

Abstract This study investigates the chemical composition and shear strength of electron beam welded joints between AISI304 stainless steel and Cu-ETP copper (2 mm). Overlapped joints were produced under different beam currents, welding speeds, and with or without beam oscillation. Microscopy and shear strength tests were applied, and results were statistically evaluated using design of experiment analysis. Higher welding speed generally reduced copper content on the fracture surface and joint strength, while increasing beam current decreased both as well. Beam oscillation improved strength only at lower welding speed (30 mm/s), but had the opposite effect at 40 mm/s. The optimum condition for maximum shear strength is a high copper content on the fracture surface. These findings provide guidance for optimizing parameters in the production of reliable dissimilar metal joints, relevant to applications in electronics and power engineering.