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TIG welding is a popular joining method for stainle ss steel (SS) which contains 16-18% of Cr and is re sponsible for its corrosion resistance and good mechanical properties. The SS w elding electrode is over alloyed with 18-22% of Cr. During TIG welding, fumes containing carcinogenic hexavalent Cr +6 are generated which are mainly from the electrode rather than the base metal and this affects the health of the welder. To mitigate these problem eight versions of nickel based Cr- free el ectrode materials were developed. After extensive literature survey and discussions w ith welding expert’s chemical composition of filler rod (electrode) is decided such that the weld joint should have good mechanical pro perties. It is well known fact that structural comp onents in addition to structural loads also experience welding induced residual stre ss. Presence of residual stresses may be favorable or harmful for the structural components depending on their nature and magnitude. Hence the main focus of the study is to perform Fi nite Element Analysis to understand the complete nature of residual stresses and distortions in butt welded joints using the ei ght novel Cr- free electrodes with base plates AISI SS304 and to determining the best weldment combination. Ansys 13, a finite element (F E) based commercial software, sequentially coupled transient thermal-me chanical, three dimensional finite element models w ere developed and the simulation was done using elemental birth and death technique. After the FE analysis it was seen that though the variation in distortions were not considerable by virtue of rest raints, the stresses in each variety of the weld sh owed notable variations of about 30MPabetween the best and the least preferred compo sition.

FINITE ELEMENT ANALYSIS OF DISSIMILAR WELDING BETWEEN NEWLY DEVELOPED CR-FREE NICKEL BASED WELDING ELECTRODE AND STAINLESS STEEL AISI 304