Processing of Copper by Keyhole-Gas Tungsten Arc Welding for Uniformity of Weld Bead Geometry

Keyhole gas tungsten arc welding (K-GTAW) was applied to characterize the weld bead geometry in case of the 6 mm thick electrolytic tough pitch copper. Various conditions of welding speeds and preheating on the bead geometry were studied for its uniformity. Visual examination, macro bead dimensional analysis, microhardness profile across the transverse section, microstructural analyses were performed to investigate the K-GTAW on electrolytic tough pitch copper. The results revealed that full penetration of 6 mm can be obtained in a single pass using keyhole mode in GTAW. Keyhole length and width were majorly affected by the welding speed and preheating temperature. Significant variations in weld bead geometry were observed even when high heat input conditions were applied without preheating. Uniform weld bead geometry of 5 mm bead width and depth to width ratio of 0.42 was obtained for a length of 80 mm using appropriate preheating of 300°C and heat input condition of 1.37 kJ/mm (resulted from 300 amperes welding current, 120 mm/min welding speed, and 15.3 volts voltage). In the uniform weld bead geometry, the weld and heat affected zones were consisted of coarse grains relative to base material, wherein the micro hardness variations were observed.