The present research work embraces the experimental studies on mechanical and metallurgical properties of powder metallurgy (P/M) plain carbon steel (Fe-0.5 %C) welded autogenously with various modes of current, namely, alternate current, direct current, mixed mode current, and pulse current (PC) using autogenous Tungsten Inert Gas (TIG) welding. The sintered specimens of rectangular shape synthesized through the P/M route were densified by cold upsetting to obtain maximum density. A pair of specimens were welded, and the weld quality was checked by standard nondestructive testing methods. Various mechanical tests were conducted using standard size specimens as per the ASTM standards. It is found from the results of various mechanical tests that the welded joint made by PC TIG welding exhibits the greatest tensile and impact strengths among the other modes of welded joint. Scanning Electron Microscopy (SEM) fractography of the tensile fractured surfaces reveal the brittle mode of fracture irrespective of the mode of welding currents, which are being used for joining the specimens. Optical microscopy, Energy Dispersive Spectroscopy (EDS), and X-ray Diffraction (XRD) analyses have been carried out to investigate microstructural changes and phase transformation of chemical constituents at the welded region. The hardness at the fusion zone is found to be higher because of pore-free microstructure.
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