Abstract
This study examines the challenges associated with joining dissimilar metals, specifically stainless steel and mild steel, and investigates the impact of electrode selection on joint quality and characteristics. Various welding processes, including shielded metal arc welding (SMAW), is explored. Experimental findings indicate that electrode choice significantly influences the formation of intermetallic compounds, fusion zone morphology, and mechanical strength of the joint. Alloying elements in electrodes are found to enhance weldability and performance by facilitating metallurgical bonding and reducing the formation of brittle phases. Furthermore, the study explores variations in welding parameters to optimize the process for desirable joint properties. By deepening our understanding of electrode roles in welding dissimilar metals, this research offers insights crucial for selecting appropriate techniques and parameters, ensuring reliable joints. These insights have broad applicability across industries such as automotive, aerospace, construction, and manufacturing, where dissimilar metal joining is common. Key Words: dissimilar metals, intermetallic compounds, Weldability, morphology, mechanical strength.
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