The main problem of dissimilar material welding is that the welding parameters are not fixed for each weld. Therefore, this study was conducted to minimize the parameters with modification of the contact surface area with the addition of V-grooves. The materials used in this research were A6061 Aluminium 6 mm thick and ASTM A36 mild steel with overlap configuration. Four parameters were studied; current, wire feed, shielding gas and V-groove angle. The research was conducted using SYNERGIC.PRO2 450-4 welding machine with 1 mm diameter of ER4042 filler material pure argon gas as shielding gas. V-groove shaped steel samples were made with various angles of 30°, 45°, and 60°. Some of the problems involving welded methods to increase solubility and prevent the development of intermetallic compounds (IMCs) to strengthen the welding joint between Aluminium and steel. Among the factors identified are the surface areas of contact during welding. One way to increase the surface area of the contact is through the construction of angular grooves on the metal surface. Tensile tests were carried out for each welded sample using Universal Testing Machine. Tensile strengths of the welded test samples ranged from 1.076 N/m2 to 48.161 N/m2.The results indicated that the Vgroove specimens have a maximum tensile strength of 48.161 N/m2. The optimum combination of welding parameters which are current of 190A, wire speed of 2 M/mm2, gas shielding of 20 L/min and V-groove angle of 60°.
