The segregation of elements and formation of a UMZ is an unfavorable but inevitable phenomenon in dissimilar welding. The present study employed conventional GMAW welding and the CMT process with the same welding parameters to clad a flux-cored Stellite 6 electrode on an A516 Grade 60 steel. The effect of the CMT welding process on the formation of UMZ in the Stellite 6 overlay was investigated. OM and SEM were used to observe the cross-section of the samples. The distribution of the alloying elements across the interface between the weld and base metals was measured using EDS analysis. It was observed that the UMZ in the CMT welding process was thinner and more uniform which was attributed to the steady arc energy and convection flow during welding. Smaller heat input, lower penetration, and higher build-up were the main reasons for uniformity and reduced UMZ width.
