metals Review Dissimilar Non-Ferrous Metal Welding: An Insight on Experimental and Numerical Analysis Jeyaganesh Devaraj , Aiman Ziout * and Jaber E. Abu Qudeiri   Citation: Devaraj, J.; Ziout, A.; Abu Qudeiri, J.E. Dissimilar Non-Ferrous Metal Welding: An Insight on Experimental and Numerical Analysis. Metals 2021, 11, 1486. https://doi.org/10.3390/met11091486 Academic Editor: Tomasz Kik Received: 15 August 2021 Accepted: 13 September 2021 Published: 18 September 2021 Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affil- iations. Copyright: © 2021 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https:// creativecommons.org/licenses/by/ 4.0/). Mechanical Engineering Department, College of Engineering, United Arab Emirates University, Al Ain 15551, United Arab Emirates; 201870228@uaeu.ac.ae (J.D.); jqudeiri@uaeu.ac.ae (J.E.A.Q.) * Correspondence: ziout@uaeu.ac.ae Abstract: In recent years Gas Metal Arc Welding (GMAW) technology has expanded its functionalities in various areas which have further motivated its usage in several emerging manufacturing industries. There are several issues and challenges associated with this technology, especially in dissimilar metal welding (DMW). One of the predominant challenges is selecting appropriate welding parameters which influence the efficiency of this technology. To explore several modern advancements in this expertise, this paper has done an exclusive survey on various standards of GMAW and its variants for selecting suitable parameters for welding dissimilar nonferrous metals. This review summarizes various experimental and numerical results along with related illustrations to highlight the feasibility of welding dissimilar nonferrous metals using traditional GMAW and investigations on advanced GMAW processes such as cold metal transfer (CMT) and pulsed GMAW (P-GMAW). Simulation and modeling of nonferrous DMW have identified several research gaps and modeling problems. Researchers and manufacturers can use this review as a guideline to choose appropriate welding parameters to implement GMAW and its variants for non-ferrous dissimilar welding. It found that by controlling the heat input and effective post-heat treatments, adequate joint properties can be achieved. Automated large -scale manufacturing will widen the utilization scope of GMAW and avoid some costly methods such as laser welding, ultrasonic welding, and friction stir welding etc. Keywords: advanced gas metal arc welding; non-ferrous dissimilar metal welding; arc welding; numerical modeling; simulation 1. Introduction In the early 1990s, electronic power control, especially the use of specific electric power converter sources, allowed better efficient control of output signal, contributing to the emergence of several unique metal transfer control methods. Such advancements further led to substantial consumer advantages and a wider variety of GMAW technologies. GMAW is a widely used process for welding both similar and dissimilar metals. Due to its versatility, speed, adaptability to robotic automation, efficiency, and economy, GMAW is preferred over other standard joining methods such as bolting, riveting, and mechanical interlocking [1]. Brazing stands in a queue followed by the welding process for DMW especially for non-ferrous metals. Though it holds an advantage over welding process in case of minimum distortion, the major fallback is the strength of the joint made through brazing will not be adequate for some industrial application [2]. Welded joints are generally stronger than bolted joints, due to the absence of perforations that reduces the load- carrying capacity of a joint. The application of GMAW are manufacturing units of the automobile industry, aerospace industry, and various manufacturing domains [3–5]. The feasibility of a product to be utilized in any practical welding application is connoted by its weldability character. Generally, the process of preventing metal cracking during welding is termed as weld- ability [6]. Due to differences in mechanical, microstructural, and thermal characteristics, Metals 2021, 11, 1486. https://doi.org/10.3390/met11091486 https://www.mdpi.com/journal/metals