Mass transport and solidification phenomenon in dissimilar metals arc welding

•Welding of dissimilar alloys is a cost-effective manufacturing process.•The possible defects such as mixing of the weld metals are serious challenges.•The numerical model is used to optimize the process parameters to improve mechanical properties.•The arc current increase led to the homogeneity of the weld zone.•The computed solidification parameters could describe the morphology of the weld zone.