Microstructure and mechanical performance of depositing CuSi3 Cu alloy onto 30CrMnSi steel plate by the novel consumable and non-consumable electrodes indirect arc welding

A novel consumable and non-consumable electrodes indirect arc welding (CNC-IAW) with low heat input was successfully applied in depositing CuSi3 Cu alloy onto 30CrMnSi steel plate. The indirect arc was generated between the consumable and non-consumable welding torch. The microstructure of the deposited weld was analyzed by means of scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS) and optical microscopy (OM). The results showed that the dilution ratio of the bead-on-plate weld was controlled no higher than 5% and the deleterious iron picking up was effectively restrained. The deposited metal mainly consisted of ε-Cu solid solution and a small amount of Fe2Si phase. In the interfacial zone between the deposited metal and base metal, the thickness of the zone changed from thick to thin and the microstructure changed from complex to simple from the middle to both sides. In the middle of the interfacial zone, the microstructure presented three sub-layers consisting of Fe3Si (L)/Fe3Si (S) + ε-Cu/α-Fe. In the both sides of the interfacial zone, the microstructure presented single α-Fe layer. The formation mechanism of the interfacial zone could be successfully explained by the formation of the Fe liquid–solid phase zone adjacent to the Fe base metal and the interfusion between Fe and Si. The average compressive shear strength reached 321 MPa and its fracture morphology mainly belonged to ductile fracture.