OSADIAYE. H. NOSAYABA

Welding is an essential fabrication process in various industries, including automotive, aerospace, shipbuilding, and construction. It is a method used to join metals or thermoplastics through coalescence, usually involving the application of heat or pressure. The welding of similar metals, such as steel-to-steel or aluminum-to-aluminum, is relatively well-understood, with established techniques and filler materials to ensure strong and reliable welds. However, welding dissimilar metals (those with different chemical compositions and physical properties) introduces additional challenges due to the inherent differences in melting points, thermal conductivity, and expansion rates.Dissimilar metal welding (DMW) has gained increasing attention in recent years due to its potential to optimize material properties in critical applications. For instance, in the automotive industry, lightweight materials like aluminum are welded to stronger metals such as steel to produce fuel-efficient vehicles without compromising safety. In the aerospace industry, DMW enables the combination of materials like titanium and aluminum, offering a balance between strength, heat resistance, and weight reduction.The role of filler materials is particularly important in DMW, as they act as intermediaries between the base metals, helping to form a stable joint. The choice of filler material influences not only the mechanical strength of the weld but also its resistance to corrosion, heat, and stress. Incompatible filler materials can lead to poor weld strength, the formation of brittle intermetallic compounds, or cracking. This study seeks to explore how different filler materials affect weld strength in DMW, with the ultimate goal of identifying the optimal materials for specific dissimilar metal combinations.