Dissimilar Materials Joining by Friction Welding

In this section

Back to Core Research Programme AMorph – 4D Printing for Field Morphing Structures Automation of Composite and Hybrid Joining Process Coaxial Wire Additive Manufacturing Processes and In-Line Monitoring Tools Development of Coded Excitation Technique for Non-Metallic Pipes Inspection Development of Digital Twin technology as a demonstrator for real-time integrity assessment of crack growth in tensile specimens Development of Friction Stir Welding (FSW) for Hydrogen Fuel Storage Tanks Development of Leak-Before-Break Hydrogen Storage Composite Pressure Vessels With Polymeric Liner Establishing Assessment Methods for Determining Safe Service Limits of High-Temperature Materials in Extreme Environments Fracture toughness in aggressive environments: effect of crack monitoring techniques on test results In-process detection and non-destructive testing of electron beam weld imperfections Internal Bore Coatings for Applications in Corrosion and Hydrogen Environment Joining of Additively Manufactured Materials Long term behaviour of polymeric liner materials/coatings in hydrogen service Techniques for High Temperature Ultrasonic Inspection of Arc Welding Ultimate Leverage Fund

Project Code: 22965

Industrial Need

Joining of dissimilar metals is a strategic need and a key challenge for many areas of industry. Successful dissimilar materials joining can be limited by many factors including thermal incompatibility, weld stability issues, chemical interactions, weld quality issues and others.

Friction welding is, in general, one of the more successful approaches that can be applied in this area, due mainly to its solid phase nature (which limits overall heat input), and the hot forging action of the process (which helps to expel the hottest material as weld flash in many cases). In very challenging applications an interlayer material can often be included in the friction welded joint, to prevent the formation of undesirable intermetallics, and thus provide an effective joint.

Project Outline

Joining of dissimilar metals is a strategic need and a key challenge for many areas of industry. Successful dissimilar materials joining can be limited by many factors including thermal incompatibility, weld stability issues, chemical interactions, weld quality issues and others. Friction welding is, in general, one of the more successful approaches that can be applied in this area, due mainly to its solid phase nature (which limits overall heat input), and the hot forging action of the process (which helps to expel the hottest material as weld flash in many cases). The primary remaining challenge in dissimilar friction welding is the potential for the generation of brittle compounds/phases within the weld, most commonly intermetallics. In very challenging applications an interlayer material can often be included in the friction welded joint, to prevent the formation of undesirable intermetallics, and thus provide an effective joint. This project will explore the use of interlayer materials for challenging dissimilar applications that are known to be of significant interest to industry.

Known industrial requirements in this area include:

Aluminium to galvanised steel – Aerospace, Automotive, Medical, Oil and Gas, Power
Titanium to aluminium – Aerospace, Construction and Engineering

Objectives

To develop procedures for effective rotary friction welding of dissimilar joints including titanium to aluminium, and aluminium to galvanised steel
To explore, if necessary, the use of suitable interlayer materials for these combinations and to characterise the benefits of including such materials in comparison to direct friction welding
To assess the repeatability of the welding procedures developed in each case

Relevant Industry Sectors

Aerospace; Automotive; Electronics and Sensors; Fabrication; Medical; Oil and Gas; Power

Dissimilar Materials Joining by Friction Welding

Industrial Need

Project Outline

Objectives

Relevant Industry Sectors

Research Board Information