Present Status of Research on Welding Technique For Al/Cu Dissimilar Materials
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Many kinds of welding methods were introduced for Al/Cu dissimilar materials,including fusion welding,pressure welding,friction welding,explosive welding,diffusion welding,ultrasonic welding,stored energy welding,resistance welding,brazing,and so on.The characteristics and present research situation of these welding methods were expounded.Fusion welding isn't mostly applied because it is greatly difficult to weld Al/Cu dissimilar materials by the fusion welding.The joint quality is excellent by heat pressure welding,friction welding,ultrasonic welding,and so on,but the cost is very high.At present,resistance welding has obtained the huge success to weld Al/Cu dissimilar material tubes and is applied in the many factories.In recent years,brazing becomes the hot research spot by many fine characteristics.Resistance welding and brazing possibly become the development trend.Keywords:
Fusion welding
Friction Welding
Explosion welding
Brazing
Cold welding
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Joining of thin sheet metals by welding was once said to be difficult as it usually burns through hole at the base metal. High welding temperature exerted on the base metal lead to cause undesirable distortion. Further challenges on joining of dissimilar materials by using fusion welding are when both base metals have different melting temperature and also might lead to breakdown of their mechanical properties. This research objective was to study the weldability of dissimilar selected metals sheet namely mild steel and galvanized iron. It was to determine the suitable welding parameters to join both metals sheet with thickness of 1.0 mm, each.  Two welding parameters identified as the welding current with a range of 34.0 – 55.5 A and wire feed speed ranging from 2.0 – 4.0 m/min, the Gas Metal Arc Welding (GMAW) process was thus employed. The samples were later tested for its tensile strength in order to get the safe welding parameter that could meet the tensile strength of the joint. It was determined that the range of safe GMAW welding parameters for both metals was 44.9 – 55.5 A of the welding current and 3.0 m/min wire feed speed.
Weldability
Flash welding
Base metal
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The aim of this project is to study and analysis various parameters which is involved in seam welding: The welding has mainly divided into two types one is fusion welding other one is pressure welding. In the pressure welding electrode is pressed against the weldment which has to be weld. The pressure welding furtherly divided in to resistance welding, smiths forge welding mechanical energy (Pressure) i.e., friction welding and chemical reaction welding. One of the most important welding are resistance spot, seam, percussion welding which are widely used in sheet metal industries. In this project we have concentrate on seam welding for different type of materials like AISI 1015 low carbon steel, nickel alloy and magnesium alloys, for analysis we have changed parameters like pressure of the electrode and welding time, whereas ANASYS have been used to determine the optimum process time
Friction Welding
Fusion welding
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Aluminium alloy has such advantages such as good conductivity,heat conductivity,light,anticorrosive and easy shaping,etc.Improving its welding productivity and quality and reducing the defect of welding have already become the urgent demand in practical production;this paper mainly introduces the welding characteristics and application situation of many kinds of aluminium alloy welding developed in recent years,such as laser arc compound welding,laser plasma welding,plasma arc welding,electron beam-plasma arc-welding,TIG-MAG welding and laser mixing friction welding,ect.
Plasma arc welding
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The use of laser in welding has ever growing role in manufacturing technology. Among the different laser welding processes the keyhole welding and keyhole welding combined with arc welding to form a so called hybrid welding are the most important laser welding process for metal industry. This process is commonly used in welding of aluminum car body parts, but not often seen in manufacture of larger aluminum products. Laser welding of aluminum is of high interest among the industrial production. High reflectivity and high thermal conductivity, high vapor pressure of alloying elements as well as low liquid surface tension and low ionization potential, make laser welding of aluminum and its alloys a demanding task for any welding method. The boats for use of authorities are often made from the aluminum. The manufacture of those is boats are usually carried out with manual welding processes. This study is concentrating on evaluation the suitability of laser welding to the manufacture of aluminum boat. This was carried out by welding a set of actual products with different welding methods and comparing those.
Plastic welding
Cold welding
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In the modern world, weight reduction plays a very important role, which improves the overall efficient of the system, Attempts are made to improve the efficiency of the system by substituting the low denser material. Joining of material is the foremost property to be considered. Temporary and permanent fastening methods are there to join but because of the requirement of the strong joint there is a need for the permanent fasting technology. Current study focuses on the pros and cons of the welding techniques of aluminum alloys. The comparison is made in between arc welding, Tungsten inert gas welding, metal inert gas welding, electron beam welding, laser beam welding, spot welding, plasma welding and friction stir welding. Each method has its own advantages and disadvantages based on the application of requirements of the selection of the welding methods are done. Friction stir welding shows the better material property with lesser crystal defects, compared to the other welding techniques. This process takes at the semi solid state, which reduces the crystal defects by providing the high strength and good welding joints. Most of the metals are failing in the heat affected zone in fusion welding along with crystal defect. Article targets to compare the different welding techniques used for aluminum joining with both similar and dissimilar metals along with limitations and the advantages.
Keywords: EBW -Electron Beam Welding, FSW -Friction stir welding, LBW- Laser Beam Welding, lpa - laser point application, MIGW- Metal Inert Gas Welding, PAW -Plasma Arc Welding, TIGW- Tungsten Inert Gas Welding.
Inert gas
Cold welding
Friction Stir Welding
Fusion welding
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Keywords: resistance weldingwelding interfacefusion weldingdiffusion weldingwelding headwelding power source
Interface (matter)
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