This study examines the microstructural evolution and mechanical properties of A500 bulletproof steel joints welded with austenitic stainless steel (ER371) and ferritic (T91) filler materials. While austenitic fillers are traditionally used in bulletproof steel welding to prevent cracking and hydrogen embrittlement, their lower hardness creates a potential weakness in welded joints. This research explores an alternative approach using a newly developed ferritic filler material to achieve strength matching with the base material. Detailed microstructural characterization was conducted using Optical Microscopy (OM) and Scanning Electron Microscopy (SEM), while mechanical properties were evaluated through tensile testing, impact testing, and hardness measurements. The results revealed significantly different mechanical behaviors between the two filler materials, with the ferritic filler achieving superior weld metal hardness (470 HV1) compared to the austenitic filler (185 HV1) in WZ. The fine-grained heat-affected zone (FGHAZ) exhibited the highest hardness (518 HV1) in A500-T91 joints and (480 HV1) in A500-ER371 joints, while ballistic testing demonstrated enhanced penetration resistance with the ferritic filler material.
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