Trends in Joining Dissimilar Metals by Welding

Abstract

The welding of dissimilar materials finds a wide variety of applications in the fields of industrial construction and manufacturing, where the characteristic features of the different materials are optimized for the desired application to result in cost effectiveness and value addition. Non-fusion welding methods such as solid state welding and high energy beam welding are more popular for welding dissimilar metal combinations, due to fewer complications, than fusion welding, which melts the base metal and forms brittle intermetallic compounds (IMCs) that may lead to failure. Various factors have to be considered when assessing the feasibility of welding dissimilar metals and producing a sound weld joint. This paper presents a broad classification of the most commonly used welding processes for dissimilar materials, discusses some of the commonly used welding processes with examples of some common material combinations, critical factors for good welding, and practical difficulties arising from the physical and chemical properties of materials. From the findings, it can be inferred that continuous improvement and research is still required in the field of dissimilar metal welding, particularly in the light of increasing demand for tailored material for modern engineering and industrial applications.

Developments of mathematical models for prediction of tensile properties of dissimilar AA6061-T6 to Cu welds prepared by friction stir welding process using Zn interlayer

“…Therefore, there are many potential applications of dissimilar Al-Cu welds. Use of fusion welding processes for joining dissimilar materials is normally not desirable due to several melting-and solidification-related issues [7] such as differences in melting points and thermal conductivities of base metals, differences in coefficients of thermal expansion of base metals, higher residual stresses, formation of brittle intermetallics, etc. Friction stir welding process is a better technique for welding dissimilar metals.…”

A Review on Welding of Dissimilar Metals in Car Body Manufacturing

“…A variety of welding processes for steel-Al alloy, Al alloy-Mg alloy and steel-Mg alloy dissimilar combinations can be broadly classified as fusion welding and solid-state welding. In the fusion welding, faying surfaces of base metals along with filler metal or without fill- 19) . The widely studied dissimilar metal welding processes are resistance spot welding 20) , friction welding 21) , friction stir welding 22) , friction stir spot welding 23,24) , laser brazing 25) , diffusion welding 26) , explosive welding [27][28][29] , impact welding 30) , ultrasonic welding [31][32][33] and magnetic pressure seam welding 34) .…”

Microstructures in interface region and mechanical behaviours of friction stir lap Al6060 to Ti–6Al–4V welds

“…However, in general, high quality joints using fusion welding are difficult to obtain. This difficulty, as recently explained by Kah et al [1] in their assessment of the current trends in welding of dissimilar metals, is due to the excessive growth of interface brittle intermetallics. Thus, joining processes during which the growth of the intermetallics is slow, such as solid state joining and brazing, are attractive for dissimilar metals joining.…”