Emerging trends in manufacturing such as light weighting, increased performance and functionality increases the use of multi-material, hybrid structures and thus the need for joining of dissimilar materials. The properties of the different materials are jointly utilised to achieve product performance. The joining processes can, on the other hand be challenging due to the same different properties. This paper reviews and summarizes state of the art research in joining dissimilar materials. Current and emerging joining technologies are reviewed according to the mechanisms of joint formation, i.e.; mechanical, chemical, thermal, or hybrid processes. Methods for process selection are described and future challenges for research on joining dissimilar materials are summarized.

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Joining of dissimilar materials

Friction welding is now well established as a means of joining many different types of materials, because it has proved itself to be a reliable and economical way of producing high quality welds. The present paper introduces different friction welding processes, their advantages and shortcomings. The history of friction welding and typical applications are also reviewed. In the context of friction welding, a number of subjects, such as frictional behaviour, joining mechanism, interface temperature and heat generation, still exist, where different concepts for explanation of the physical mechanisms have been proposed by different investigators. To clarify some inconsistencies in the interpretation of the friction welding process, a thorough review and critical assessment of the literature associated with this process is attempted.

Friction welding – critical assessment of literature

Friction welding is now well established as one of the most economical and highly productive methods in joining similar and dissimilar metals. It is widely used in automotive and aerospace industrial applications. Friction welding is often the only viable alternative in this field to overcome the difficulties encountered in joining the materials with widely varying physical characteristics. This process employs a machine that is designed to convert mechanical energy into heat at the joint to weld using relative movement between workpieces, without the use of electrical energy or heat from other sources. This review deals with the fundamental understanding of the process. The focus is on the mechanism of friction welding, types of relative motions of the process, influence of parameters, heat generation in the process, understanding the deformation, microstructure and the properties of similar and dissimilar welded materials.

Bekir S. Yibaş

Papers

Analysis of the friction welding process in relation to the welding of copper and steel bars