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

The mass saving potential of light-weight materials, such as Al alloys, is beneficial for fuel economy and reducing CO2 emissions. However, the wide-spread use of these alloys has been long hindered due to the difficulty in fusion joining as well as their high cost. Welding of Al alloys, which are considered to be difficult to weld through conventional arc welding, is now possible by either of low heat input arc welding, high-power density fusion joining, such as laser beam welding and electron beam welding, or friction stir welding. Particularly, friction stir welding can be successfully applied to these materials owing to the fact that no melting takes place in the weld nugget. The aim of this overview is to summarize the developments in the joining of Al alloys over the recent years. This study is also intended to provide guidance for the industry and researchers dealing with joining of these alloys.

Recent developments in joining of aluminum alloys

Although wire arc additive manufacturing (WAAM) has proven its capability of fulfilling demands of production of medium-to-large-scale components for automotive and allied sectors made up of alumin...

A review of wire arc additive manufacturing and advances in wire arc additive manufacturing of aluminium

Prospects of laser beam welding and friction stir welding processes for aluminum airframe structural applications

Cold metal transfer (CMT) technology - An overview

Dissimilar friction welding of 6061-T6 aluminum and AISI 1018 steel: Properties and microstructural characterization

Mechanical and microstructural properties of robotic Cold Metal Transfer (CMT) welded 5083-H111 and 6082-T651 aluminum alloys

Mechanical, fatigue and microstructural properties of friction stir welded 5083-H111 and 6082-T651 aluminum alloys

Laser welding of modified 12% Cr stainless steel: Strength, fatigue, toughness, microstructure and corrosion properties

In this study, conventional fusion welding processes: MIG, TIG and solid state process friction stir welding (FSW) were applied to 6.45 mm thick plates of 5086-H32 aluminium alloy. The weldments were evaluated by performing microstructural examinations including light optical microscope (LOM) and transmission electron microscope (TEM) and EDX analysis as well as hardness measurements. Mechanical testing has been done by means of tensile and bend tests. Fracture surfaces were examined by LOM and scanning electron microscope (SEM). Depending on the properties obtained, it has been determined that double pass friction stir welded joints of 5086-H32 aluminium alloy have superior properties than that of MIG and TIG welded joints.

Comparison between microstructure characteristics and joint performance of 5086-H32 aluminium alloy welded by MIG, TIG and friction stir welding processes

Emel Taban

Papers

Dissimilar friction welding of 6061-T6 aluminum and AISI 1018 steel: Properties and microstructural characterization

Mechanical and microstructural properties of robotic Cold Metal Transfer (CMT) welded 5083-H111 and 6082-T651 aluminum alloys

Mechanical, fatigue and microstructural properties of friction stir welded 5083-H111 and 6082-T651 aluminum alloys

Laser welding of modified 12% Cr stainless steel: Strength, fatigue, toughness, microstructure and corrosion properties

Comparison between microstructure characteristics and joint performance of 5086-H32 aluminium alloy welded by MIG, TIG and friction stir welding processes