In this research, dissimilar joint properties of pure Cu to AISI304 stainless steel using three different filler metals were studied. In this regard, the welding process was done with gas tungsten arc welding process using ER308L, ER309L, and ERNiCrMo3 filler metals and ERNi1 butter layer. The microstructural evaluations were carried out using optical microscope and scanning electron microscope. The mechanical tests were conducted by microhardness, tensile, bending and impact tests, and the fracture surfaces of impact and tensile tests were studied by scanning electron microscope. The results show that there is no crack or discontinuity in the welded samples. Energy-dispersive spectroscopy analysis revealed that the diffusion of Cu from base metal to butter layer has been occurred during welding. The microhardness profiles indicated the increase of hardness in heat-affected zone and butter layer. The welded sample with ERNiCrMo3 filler metal showed higher microhardness (200 HV) as compared with two other welded samples. The welded sample with ER309L filler metal had lower microhardness of about 150 HV. The tensile test revealed that the welded sample with ER309L filler metal showed maximum (193MPa) and the welded sample with ER308L showed minimum (147MPa) of ultimate tensile strength. In bending test of the welded samples with ER308L and ERNiCrMo3 filler metals, the crack and discontinuity were revealed in weld metal and heat-affected zone of Cu, respectively, while in the welded sample with ER309L filler metal no crack and discontinuity were seen. Also the welded sample with ER309L filler metal had highest impact energy of about 90 J as compared to other samples (81 and 88 J for the welded samples with ER308L and ERNiCrMo3 filler metals, respectively). The welded sample with ER309L filler metal showed more ductile fracture surface as compared with other samples.
