Material weldability
Aluminum Welding
The self-generating oxide layer on aluminum creates both corrosion resistance and welding challenges. Rapid thermal dissipation demands specialized heat control protocols. Grade-A welds achievable with proper methodology despite porosity risks.
Beryllium Copper Welding
This specialty copper alloy achieves military-grade strength while maintaining conductivity through controlled beryllium addition (0.5-3%). Its non-magnetic and spark-resistant properties make it ideal for precision instruments and explosion-proof tools. Requires professional fume extraction due to toxic beryllium emissions at elevated temperatures.
Copper Welding
Pure copper’s face-centered cubic structure delivers exceptional 58 MS/m electrical conductivity and 401 W/(m·K) thermal transfer capability. The distinctive rose-gold metallic luster makes it irreplaceable in electrical and artistic applications. High hydrogen solubility and rapid oxidation in molten state necessitate material grade selection.
Chromoly Steel Welding
The Fe-Cr-Mo ternary system achieves 30% higher specific strength than carbon steel through dual strengthening mechanisms (Cr solid solution & Mo precipitation). Self-regenerating passivation film in oxidative/sulfuric environments makes it ideal for aerospace structures and racing chassis. Requires meticulous phase transformation control during welding.
Hastelloy Welding
This nickel-based superalloy establishes triple-defense matrix (Ni≥45%, Mo 15-17%, Cr 14-16%) enabling full pH-range corrosion resistance in extreme environments. FCC structure maintains creep resistance up to 650°C, making it the ultimate choice for chemical reactors and nuclear containment. Requires precise γ’ phase control to prevent intergranular embrittlement.
Inconel Welding
This austenitic Ni-Cr superalloy employs γ” phase strengthening (Ni≥58%, Cr 14-17%, Fe≤10%) to establish triple-protection: gaseous oxidation barrier, intergranular corrosion immunity, and stress corrosion cracking resistance. Self-regenerating oxide scales (Cr₂O₃/Al₂O₃ bilayer) maintain structural integrity under 1200℃ thermal shocks, making it critical for jet engine combustors and nuclear pressure vessels. Requires precise Laves phase control during welding.
Iron Welding
Pure iron’s BCC structure exhibits characteristic α→γ phase transition (912℃ critical point) governing welding metallurgy. Although base yield strength (~80MPa) is moderate, triple strength enhancement achievable via strain hardening. Essential for structural engineering despite requiring anti-corrosion treatments. High carbon solubility (2.1wt%) in molten state causes segregation risks.
Kovar Welding
The Fe-Ni-Co ternary system achieves near-perfect thermal expansion matching (4.5-5.6×10⁻⁶/℃, 20-400℃) with borosilicate glass through precise composition control (Ni 29%, Co 17%, Fe balance). FCC structure maintains ±0.01% dimensional stability from -60℃ to 450℃, making it critical for aerospace electronics and laser hermetic sealing. Requires metallurgically clean surfaces free from platings.
Magnesium Alloy Welding
Featuring HCP crystal lattice, this ultralight alloy (1.8g/cm³) achieves unparalleled specific stiffness (45GPa·cm³/g) through Al/Zn/Mn solid solution strengthening. Dynamic recrystallization accelerates above 250℃, while native oxide film (MgO/Mg3N₂) rupture triggers exothermic reactions demanding absolute inert atmosphere. Critical for aerospace lightweighting and biodegradable implants.
Molybdenum Welding
This refractory BCC metal (2620℃ MP) achieves intrinsic stability via electron-beam zone refining (99.97% purity): maintains 138W/(m·K) thermal conductivity up to 2000℃ with vapor pressure <10⁻⁶Torr below 1800℃. <100> texture evolution necessitates rare-earth doping (La₂O₃/Y₂O₃) to prevent recrystallization embrittlement. Critical for semiconductor processing equipment and high-temperature crucibles.
Monel Welding
The Ni-Cu marine alloy (Ni 52-67%) combines γ-phase solid solution and κ-phase precipitation strengthening, maintaining <0.01mm/yr corrosion rate in seawater/H₂S environments. FCC structure exhibits paradoxical work-hardening behavior from -196℃ to 480℃, making it vital for subsea Xmas trees and naval propulsion systems. Welding requires overcoming liquid metal embrittlement and HAZ σ-phase formation.
Nickel Welding
Nickel’s FCC lattice provides exceptional ductility (≥50% elongation) and creep resistance (≥80MPa at 650℃). As one of few ferromagnetic engineering metals (Curie point 358℃), it’s irreplaceable in high-field environments. High-purity variants (≥99.9%) prove strategic in PEM electrolyzers and superalloy substrates, though high sulfur solubility (0.005wt%) in molten state risks grain boundary weakening.
Stainless Steel Welding
Chromium-based alloys (Cr≥10.5%) achieve self-healing corrosion resistance through dynamic passivation film regeneration (Cr₂O₃·nH₂O). Austenitic/ferritic/martensitic multiphase systems maintain structural integrity under extreme pH conditions. Duplex variants (PREN≥40) leverage phase synergy (γ+α≤50%) for chloride stress corrosion breakthrough. Welding thermal cycles may induce σ-phase embrittlement (650-950℃ sensitivity) and intergranular attack risks.
PH Stainless Steel Welding
This age-hardening stainless steel achieves unprecedented strength-ductility synergy (≥1500MPa UTS with 16% elongation) via controlled nano-intermetallic precipitation (Ni₃Ti/Cu-rich). The dual-phase strengthening – martensitic matrix load-bearing plus precipitate pinning – redefines performance in aerospace fasteners and surgical implants. Welding thermal cycles disrupt precipitation sequences, requiring in-situ aging to restore nanostructure.
Steel-High Carbon Welding
With controlled carbon content (0.6-1.0wt%C), this steel develops lamellar pearlite-martensite architecture achieving 1900MPa ultimate strength with 8% elongation. BCC lattice enables self-sharpening phase transformation during quenching, making it ideal for cutting tools and fatigue-resistant springs. Welding thermal cycles risk grain boundary carbide networks, demanding dynamic phase engineering for nanostructured carbide dispersion.
Steel-Medium Carbon Welding
With controlled carbon gradients (0.3-0.6wt%C), this steel develops pearlite-ferrite-bainite tri-phase microstructure, achieving optimal fracture toughness (KIC≥90MPa√m) and formability within 650-850MPa strength range. BCC/FCC interphase boundaries provide exceptional fretting wear resistance, making it critical for automotive suspension and hydraulic systems. Requires metallurgical preconditioning to prevent HAZ martensitic anomalies.
Steel-Low Carbon Welding
With ferrite-pearlite dual-phase microstructure (C≤0.20%), mild steel achieves optimal formability (≥25% elongation) at 5% the cost of carbon fiber composites. BCC lattice slip system activation makes it ideal for automotive stampings and structural frameworks. Requires grain growth suppression and cold crack prevention during welding.
Tantalum Welding
Featuring BCC structure with 5.0g/cm³ density and 302W/(m·K) thermal conductivity, tantalum exhibits zero corrosion rate in aqua regia. EB-melted grade (99.995% purity) maintains grain boundary integrity under plasma bombardment, making it irreplaceable in semiconductor reactors and bio-implants. Extreme sensitivity to interstitial elements (O/N/H solubility <1ppm) demands ultrapure welding environments.
Titanium Welding
Titanium’s HCP/BCC dual-phase structure, enhanced by beta-stabilizing elements (Al/V/Mo), achieves aerospace-grade strength (≥900MPa) with biocompatibility. The self-healing 5-20nm TiO₂ film resists extreme corrosion, while molten titanium’s oxygen/nitrogen sensitivity (solubility differential >10³) demands 99.999% inert gas shielding. Critical for subsea systems and medical implants.
Tungsten Welding
Featuring BCC lattice with 19.3g/cm³ density and 3422℃ melting point, tungsten maintains structural integrity under >3000℃ plasma flux. 〈111〉 texture evolution necessitates rare-earth oxide (La₂O₃/Y₂O₃) grain boundary engineering to elevate recrystallization threshold by 500℃. Dominates fusion reactor first walls and kinetic penetrators, though intrinsic brittleness (plasticity＜3%) demands atomic-level thermal management during welding.