The Joining of Copper to Stainless Steel by Solid-State Welding Processes: A Review

Abstract

Joining immiscible materials such as copper and stainless steel together is a significant concern due to distinct mechanical and metallurgical properties across the joint line, such as melting points, the coefficient of linear thermal expansion, and thermal conductivity. The joint properties of copper to stainless steel welds are in great demand for various mechanical components of the international thermonuclear experimental reactor, ultra-high vacuum system, plan wave linear-accelerator or linac structure, and heat exchanger. These dissimilar-metals joints offer excellent flexibility in design and production, leading to a robust structure for many cutting-edge applications. Hence, the present article reviews the copper to stainless steel joining mechanism under different solid-state processing conditions. The present understanding says that defect-free strong joints between the dissimilar metals are systematically possible. Apart from this understanding, the authors have identified and highlighted the gaps in the research exploration to date. Moreover, a sustainable methodology to achieve a desirable weld of copper to stainless steel depends on favorable processing conditions.

Assessing crack susceptibility in blended copper-stainless steel compositions during laser directed energy deposition-based additive manufacturing

“…3 In recent times, there has been a growing interest among research groups in Cu-SS joints considering its wide potential applications in the above-mentioned sectors. [4][5][6][7] Metallurgical incompatibility and the diverse nature of Cu and SS due to the large difference in thermal expansion coefficient, and thermal conductivity leads to porosity and cracking during their welding. 4 In addition, the poor solubility of Cu and SS with each other causes unstable and complex melt-pool dynamics leading to solidification cracking and porosity during joining.…”

“…[4][5][6][7] Metallurgical incompatibility and the diverse nature of Cu and SS due to the large difference in thermal expansion coefficient, and thermal conductivity leads to porosity and cracking during their welding. 4 In addition, the poor solubility of Cu and SS with each other causes unstable and complex melt-pool dynamics leading to solidification cracking and porosity during joining. [4][5][6] Solidification cracking is the major source of cracking in the Cu-SS system due to a large solidification range and large difference in the thermal expansion coefficient.…”

Theoretical Analysis and Verification on Plastic Deformation Behavior of Rocket Nozzle Using a Novel Tube Upsetting-Bulging Method

“…In addition, due to the influence of friction caused by high pressure, the material of the tube has difficultly flowing, which can cause serious thickness thinning or even cracking [ 18 , 19 ]. As a result of the limitation of the ultimate expansion coefficient of the tube, the maximum expansion rate of the tube section is generally 20–33% [ 20 ].…”

Experimental Investigation and Characterization of Friction Stir Spot-Welded Dissimilar Aluminum Copper Metallic Lap Joints

“…Welding of dissimilar metals has gained more attention since its importance and application are in great demand in the industrial sector. Solid state welding ensures ease of welding dissimilar metals, namely aluminum and copper. , Metallurgical incompatibility and postprocessing requirements with traditional welding techniques are addressed with the solid-state welding process. , In addition, solid-state welding techniques offer a high strength-to-weight ratio, formability, and high speed of operation in joining parts. Friction stir spot-welding (FSSW) does not require lateral tool movement to produce such joints .…”

“…Solid state welding ensures ease of welding dissimilar metals, namely aluminum and copper. 1 , 2 Metallurgical incompatibility and postprocessing requirements with traditional welding techniques are addressed with the solid-state welding process. 3 , 4 In addition, solid-state welding techniques offer a high strength-to-weight ratio, formability, and high speed of operation in joining parts.…”