Comparative Analysis of GTAW, LBW, and FSW Welding Techniques for Dissimilar Weld Joints of SS 304 and Mild Steel (E 250A) Plates

Dissimilar metal welding is a crucial process in industries requiring the joining of materials with different properties to optimize performance and cost. This study focuses on a comparative analysis of three advanced welding techniques: Gas Tungsten Arc Welding (GTAW), Friction Stir Welding (FSW), and Laser Beam Welding (LBW) for joining stainless steel (SS 304) and mild steel (E 250A) plates. These materials are commonly used in structural and industrial applications due to their mechanical strength, corrosion resistance, and cost-effectiveness. The analysis evaluates the weldability, mechanical properties, and microstructural characteristics of joints produced by each technique. Key performance metrics such as tensile strength, hardness, microstructural behavior, and residual stress distribution are compared. The study aims to identify the most suitable welding technique for dissimilar joints of SS 304 and mild steel, balancing mechanical performance, process efficiency, and economic feasibility. The results will provide valuable insights for industries involved in manufacturing, automotive, and construction, guiding the selection of optimal welding techniques for hybrid material assemblies.