The effect of ferrite band in this investigation for the prevention of Copper’s atomic diffusion to steel’s grain boundaries and the resulting cracks during cladding of Aluminum Bronze alloy on Carbon Steel. Thus, the conventional gas tungsten arc welding (GTAW) method with the direct current and straight polarity (DCSP) was applied to coat carbon Steel by means of ERCuAl-A2 filler material. Bronze filler wire containing Si (ERCuSi-A) along with Aluminum Bronze (ERCuAl-A2) filler were used, in order to form ferrite band. Optical Microscopy, Scanning Electron Microscopy and Electron Back Scattered Diffraction. A scientific and statistical project were used and a design of experiments (DOE) method exerted to prognosticate the conditions of 4.18 %wt. Si in ferrite band. Experiments were performed using a respond surface method (RSM) and considering three levels for filler’s Si content, Heat Input, and Overlap, each one. MINITAB (18) software was used to analyze the data attained by respond surface technique. The clads’ local corrosion behavior of specimens with the Si content of 0, 3.80, and 7.60 %wt. was assessed through the Cyclic Polarization test in 3.5% Sodium Chloride solution. Ferrite Band prevented the diffusion of Cu melt into the Steel’s grain boundaries when Aluminum Bronze with 3.8 %wt. Si was deposited. Nevertheless, the Ferrite’s dissolution and phase change into Austenite zone and consequently the Cu permeation in Steel’s grain boundaries occurred when Overlapping of the mentioned Clad with passes was produced. The results of the respond surface method demonstrated that the diffusion of Cu liquid into grain boundaries of steel’s HAZ was not observed the cladding was performed with 7.6 %wt. Si and in minimum heat input. In Cyclic Polarization test, the pitting corrosion was not observed in clad which had no Si content, due to the establishment of negative hysteresis ring. Although the pitting sensitivity is low in the clad containing 7.6 %wt. Si, it showed the lower pitting corrosion resistivity compared to the one containing 3.8 %wt. Si. Key words: Cladding, Aluminum Bronze, Diffusion of Cu Melt, Bronze Containing Si, Ferrite Band, Respond Surface Method.
