Innovative Welding Technique for Lightweight Dissimilar Materials

Abstract

The necessity of joining dissimilar materials commonly occurs in various industrial applications, for example, aerospace, automotive, and manufacturing. This requirement begins due to the demand for lightweight engineering structures with improved performance. Friction stir welding (FSW) is one of the leading techniques adopted extensively in joining dissimilar lightweight materials. FSW is a solid-state-based joining technique that has a significant role in joining of dissimilar materials, for example, joining of Al with Mg, Cu, steel, aluminum-titanium, etc. Joining these combinations of dissimilar materials is difficult due to different melting points and pernicious reactions during welding, which results in an undesirable phase. This problem can be solved using the FSW process as it requires low energy inputs and provides very low distortion compared to other fusion welding techniques. It improves the welding properties of dissimilar materials combined with results in less distortion and minimal residual stress and weld defects. This chapter provides an in-depth discussion about FSW of dissimilar materials, its process parameters and various zones that occurred after joining, tool materials, and tool design. © 2024 selection and editorial matter, Pankaj Kumar, Manowar Hussain, Amit Kumar Jain and Sunil Pathak

individual chapters, the contributors.