The dissimilar metal weld (DMW) is widely used in fabrication and manufacturing in various industries. Joining between nickel-based alloy and ferritic steel tubing and piping is commonly employed for ASME Code compliant welds for high-temperature and corrosion resistance applications. A series of DMW samples between alloy 600 pipe and SA-106 Grade B pipe are fabricated using different welding processes, joint design and welding techniques. By detailed comparison, this paper provides insight into the effects of these different welding variables on mechanical properties (tensile properties and hardness of weld materials and heat affected zone), metallurgical properties (macro and microstructure examination) and chemistry (root pass alloying dilution etc.). It has been shown that an asymmetric joint bevel design in consideration of different heat dissipation, melting temperature of the two materials will promote good weld bead formation during the root pass welding. Different joint designs (such as with or without consumable insert) will create variations on weld dilution and Cr/Ni recovery in the root area. Other welding variables such as tungsten electrode location for root pass welding for DMW, machine Gas Tungsten Arc Welding (GTAW) using hot wire and cold wire, etc. are also discussed.
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