Feasibility Studies on Welding of Titanium with Stainless Steel with Different Filler Material Combinations Using Electron Beam Welding
Vankudoth Ravinder*1, Suresh Arjula2
1Vankudoth Ravinder, Department of Mechanical, Malla Reddy College of Engineering, Medchal, Telangana (Hyderabad), India.
2Dr. Suresh Arjula, Department of Mechanical, Malla Reddy College of Engineering, Medchal, Telangana (Hyderabad), India.
Manuscript received on 02 August 2026 | First Revised Manuscript received on 09 August 2026 | Second Revised Manuscript received on 27 August 2026 | Manuscript Accepted on 15 September 2026 | Manuscript published on 30 September 2026 | PP: 4-11 | Volume-13 Issue-9, September 2026 | Retrieval Number: 100.1/ijies.I1124120101025 | DOI: 10.35940/ijies.I1124.12010125
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© The Authors. Blue Eyes Intelligence Engineering and Sciences Publication (BEIESP). This is an open-access article under the CC-BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Abstract: This review paper highlights the essential role of machine learning models in improving weld quality and optimising welding processes, with a strong focus on ML’s revolutionary applications in electron beam welding. By adopting these innovations, the industry can confidently unlock new levels of efficiency and excellence in welding technology. The formation of brittle Ti–Fe intermetallic compounds (IMCs) and thermal property mismatches make welding titanium and stainless steel difficult. Electron Beam Welding (EBW) can join these dissimilar metals under high vacuum, providing precise control and minimal contamination. The study investigates various filler and interlayer materials, including graded stacks and Nb, Ta, V, Mo, Cu, and Ni. The study assesses how well these materials strengthen joints, reduce IMC formation, and increase corrosion resistance. While Ni may promote brittle phases, refractory metals like Nb and Ta are predicted to perform best. The results will help determine workable welding parameters and filler materials. Brittle Ti–Fe intermetallic compound (IMC) formation and thermal-property mismatches make welding titanium and stainless steel difficult. This study investigates the viability of various filler and interlayer materials, including graded stacks and Nb, Ta, V, Mo, Cu, and Ni. The results will help identify workable filler materials and welding parameters for dependable Ti–SS joints. Furthermore, the study offers a comparative framework that businesses can use to guide dissimilar-metal joints in advanced engineering applications that are lightweight, corrosion-resistant, and mechanically dependable. Main objective statement: This project investigates the feasibility of welding titanium alloy (Ti-6Al-4V) to stainless steel (304L/316L) using electron beam welding and different filler materials (Ni, Cu, V). The study aims to analyse how filler materials affect weld quality, microstructure, and mechanical properties to identify the most suitable filler for high-strength applications. Main task: This project welds titanium alloy (Ti-6Al-4V) to stainless steel (304L/316L) using electron beam welding with different filler materials (nickel, copper, vanadium). The welds will be analysed for microstructure and mechanical properties to identify the most suitable filler material for producing strong, defect-free joints.
Keywords: LBM, Machine Learning, Performance, Efficiency, Material Characterisation, Filler Material Selection, and Weldability Testing. Diffusion Barrier, Beam Offset, Heat Input, Microstructure, Mechanical Properties, Residual Stress, Titanium, Ti-6Al-4V, Commercially Pure Titanium, Stainless Steel, 304L 316L, 410/420, Intermetallic, Interlayer, Filler, Copper, Nickel, Vanadium, Niobium, Tantalum, Molybdenum, and Feasibility.
Scope of the Article: Mechanical Engineering