This study investigates the failure of a dissimilar welded joint within the structure of an electric transmission line. A progressive failure mechanism is observed in the welded joint, which is subsequently introduced into the structural analysis. Finite Element (FE) models are developed to simulate and analyze the failure behavior of dissimilar welded joints. The objective of the analysis is to identify the optimal combination of dissimilar materials for structural applications in electric transmission lines. To assess the microstructural characteristics, grain size, crystallographic orientation, and grain boundary mismatches are
examined using Electronic Back-Scattered Diffraction (EBSD). Additional microstructural characterization is performed through fractographic analysis, Energy Diffraction Scattered (EDS), and Scanning Electron Microscopy (SEM). Tensile testing is conducted on dissimilar welding joints (comprising mild steel–stainless steel (MS–SS), mild steel–galvanized iron (MS–GI), and stainless steel–galvanized iron (SS–GI) combinations). Experimental results indicate that the MS-SS welded joint exhibits superior mechanical strength compared to the MS-GI and SS-GI.