Method and system for welding inconel to stainless steel

A. robotic, gas metal arc welding (GMAW) system, comprising:

• a welding robot including a welding torch and a weld wire feeder configured to deliver a continuous weld wire to a contact tip of the welding torch during welding;
• a welding power source in communication with the welding robot to provide a power output to the welding torch and with the weld wire feeder to provide power to the weld wire feeder;
• and
• a robot controller in communication with the power source and the welding robot, the robot controller configured to:
• control the power source to deliver an output to the welding torch, during welding an Inconel part having a first thickness to a stainless steel part having a second thickness, that is in the range of 100 amps to 400 amps and in the range of 14 volts to 30 volts;
• and
• control the weld wire feeder during welding the Inconel part to the stainless steel part to deliver the weld wire to the distal tip of the welding torch at a feed rate in the range of 3 m/min. to 9 m/min.

A method of gas metal arc welding (GMAW) an Inconel diffuser to a stainless steel end plate of an EGR cooler using a welding system having a welding power source, the method comprising:

• forming a weldable joint between an end surface of the Income diffuser and a peripheral surface of the stainless steel end plate, wherein the Inconel end surface has a first thickness and the steel plate has a second thickness that is greater than the first thickness at the weldable joint;
• welding the Inconel diffuser to the stainless steel end plate along the weldable joint with the welding torch;
• delivering an output from the welding power source to the welding torch during welding, wherein the output of the welding, power source is in the range of 100 amps to 400 amps and in the range of 14 volts to 30 volts;
• delivering a continuous weld wire to a contact tip of the welding torch during welding, wherein a feed rate of the weld wire is in the range of 3 m/min. to 9 m/min.