Tensile Strength Property Optimization of Tungsten Inert Gas Welding Process on Steel Chip Reinforced Copper Composite Joint

Abstract

This study optimizes the tensile strength of Tungsten Inert Gas (TIG) welded steel chip-reinforced copper composite joints, crucial for aerospace, automotive, and construction industries. Copper matrix composites offer superior mechanical, thermal, and electrical properties, but welding parameter optimization remains challenging. The research employed Response Surface Methodology (RSM) with the Box-Behnken design to vary TIG welding parameters—current, voltage, and gas flow rate. Copper composites reinforced with steel chips were produced via stir casting and welded under different conditions. Current was the most significant factor affecting tensile strength, with an impact coefficient of 8.50, followed by voltage (3.5) and gas flow rate (2.25). The highest tensile strength of 149 MPa was achieved at 119 amps, 25 volts, and 13 liters/min. The model, with R<sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup> = 0.9181, demonstrated high reliability. The study's novelty lies in its detailed optimization of welding parameters, providing a validated model to significantly enhance the tensile strength of copper composites. These findings are valuable for improving material performance in industries requiring strong, reliable welds. Future research could explore these composites' thermal and electrical properties for broader engineering applications.