Gürol, UğurÇelik, CerenÇoban, OzanGöçmen, MüesserKoçak, Mustafa2024-12-192024-12-1920252352-492810.1016/j.mtcomm.2024.1112092-s2.0-85211054132https://doi.org/10.1016/j.mtcomm.2024.111209https://hdl.handle.net/11501/1579Armor steels are widely recognized for their exceptional mechanical and ballistic performance, particularly in the fabrication of armored vehicles. Austenitic stainless steel (ASS) wires are commonly used in their welding processes to mitigate hydrogen-induced cracking. However, joints formed using ASS often suffer from reduced ballistic performance due to the strength mismatch (undermatching) compared to the base material. This study explores the application of butt joints, integrating low hydrogen ferritic (LHF) deposits between softer ASS weld layers, which can be expressed as sandwich layer design, in gas metal arc welded (GMAW) armor steel plates. The mechanical properties were evaluated through hardness, tensile, and Charpy V-notch impact tests. Ballistics test performances were measured using depth of penetration (DoP) and width of penetration (WoP) values. The microstructural analysis utilized stereo, optical, and scanning electron microscopes. The results demonstrated that the sandwich joint configuration met the Charpy-V impact toughness requirements of the base metal, achieving 31.4 J and 65 J at −40 °C for the WM and HAZ regions, respectively, compared to 20 J for the base material. Moreover, this innovative joint design effectively combined the high toughness and ductility of austenitic wire, reaching a low DoP value of 7.2 mm, with the superior strength of ferritic filler metal, which contributes to a low WoP value of 12.5 mm and a joint efficiency of 48 %. By combining these properties, the joint design significantly enhances ballistic performance in welded regions, traditionally considered vulnerable to ballistic threats, without compromising overall mechanical integrity.eninfo:eu-repo/semantics/closedAccessGas Metal Arc WeldingHigh StrengthLow Alloy SteelMechanical PropertiesMicrostructureSandwich JointStrength UndermatchingArticleQ242WOS:001374566300001Q2