Showing papers on "Cold welding published in 2006"
TL;DR: The cold metal transfer (CMT) is an automated welding process based on dip transfer welding, characterised by controlled material deposition during the short circuit of the wire electrode to the workpiece as mentioned in this paper.
Abstract: Cold metal transfer (CMT) is an automated welding process based on dip transfer welding, characterised by controlled material deposition during the short circuit of the wire electrode to the workpiece. Preliminary results are presented examining the suitability of this process for welding aluminium alloy. Trials show that in comparison with pulsed metal inert gas (MIG) welding, CMT exhibits a higher electrode melting coefficient. By adjusting the short circuit duration penetration can be controlled with only a small change in electrode deposition. Furthermore, by mixing pulsed MIG welding with CMT welding the working envelope of the process is greatly extended allowing thicker material sections to be welded with improved weld bead aesthetics.
192 citations
TL;DR: In this paper, it was pointed out that friction stir welding capability especially brass plates which are 3mm in thickness can be used for fusion welding of brass materials and the experiment conditions were determined and friction stir weld procedures were applied to brass plates in different rotation and welding speeds.
110 citations
TL;DR: In this article, the formation of characteristic interfacial oscillations with vortices at high energetic conditions was identified as FeTi and Fe2Ti intermetallics by X-ray diffraction and smooth wavy and flat topography was obtained for thin flyer plates due to less kinetic energy loss.
Abstract: Commercially pure titanium and 304 stainless steel were welded using explosive welding technique. The joints were evaluated using optical microscope, scanning electron microscope, energy dispersive spectroscopy and X-ray diffraction. The study indicates the formation of characteristic interfacial oscillations with vortices at high energetic conditions. The reacted products of the vortices have been identified as FeTi and Fe2Ti intermetallics by X-ray diffraction. Increase in the kinetic energy spent at the interface cause the volume of vortices to increase. Smooth wavy and flat topography has been obtained for thin flyer plates due to less kinetic energy loss. The results demonstrate a good welding interface for multi-layered welding using a thin stainless steel interlayer, as the kinetic energy dissipation at the interface was less. [doi:10.2320/matertrans.47.2049]
108 citations
15 Aug 2006-Materials Science and Engineering A-structural Materials Properties Microstructure and Processing
TL;DR: In this article, a large number of transverse cracks were found in the weld fusion zone in laser and hybrid laser/arc welding of high strength aluminium alloys, and it was found that the cracking is related to the elongated temperature distribution in the welding direction.
Abstract: In laser and hybrid laser/arc welding of high strength aluminium alloys, a large number of transverse cracks were found in the weld fusion zone. The cracking behaviour was evaluated experimentally and scanning electron microscopy images of crack surfaces confirmed that the cracks occurred when the weld fusion zone was in the semi-solid state. Thermal histories in the workpiece under representative welding conditions were measured and constitutive modelling of thermo-mechanical behaviour in the weld was performed. It was found that the cracking is related to the elongated temperature distribution in the welding direction, which induces a transverse tensile strain in the weld fusion zone during the cooling phase. One of the possible solutions to the cracking problem is to use an additional heat source to alter the temperature distribution and thus to reduce the cracking tendency. The effect of welding with an appropriately placed secondary heat source was verified by experimental tests.
77 citations
TL;DR: In this article, the authors present an experimental study on the complex physical phenomena occurring during the interaction between the plasma plume, the laser beam and the shielding gas by using an in-process spectroscopic investigation of the plume characteristics under different operating conditions.
66 citations
TL;DR: In this paper, the authors examined the laser hybrid welding process using high speed video in order to understand the relationship between bead formation and the relative locations of the laser beam, arc and molten wire droplet during aluminium butt joint welds.
Abstract: In recent time there has been vigorous development of laser hybrid welding technology for applications in numerous industrial fields. Many of those research achievements have already been reported to relevant technology users. However, there are many issues still requiring further research and development, including more comprehensive understanding of the various welding phenomena in laser hybrid welding. In the present study, therefore, the laser hybrid welding process was examined using high speed video in order to understand the relationships between bead formation and the relative locations of the laser beam, arc and molten wire droplet during aluminium butt joint welds. It is apparent from the results of experiments and observations of high speed images that the heat input delivered to the plate is dependent on the nature of the leading heat source and also the joint condition used in hybrid set-up. In particular the presence of a gap in the joint changes the heat transfer efficiency and elec...
45 citations
TL;DR: In this paper, a new welding method, magnetic pressure seam welding, was used to lap join dissimilar metals (Al-Fe, Al-Ni and Al-Cu), and strong lap joints were obtained for every metal combination.
Abstract: A new welding method, magnetic pressure seam welding, was used to lap join dissimilar metals (Al-Fe, Al-Ni and Al-Cu). The circuit for magnetic pressure seam welding consists of a capacitor, an electric discharge gap switch, and a plate-type coil. The overlapped metal plates are placed over the coil. When an impulse current from an energy-storage capacitor bank passes through the coil, a high-density magnetic flux is suddenly generated around the coil. The generated high-density magnetic flux lines cross the end of the overlapped plates. Eddy currents are induced mainly inside the Al plate because it has a high electrical conductivity. Both the Joule heat generated in the plates and the magnetic pressure applied from the Al side promote the joining of the lapped plates. The welding is normally achieved within 10 μs. This results in very little microstructural change in the parent plates aside from the area around the weld interface. Strong lap joints were obtained for every metal combination and no tensile fracture took place in the weld region. A characteristic wavy morphology was observed at the weld interface. An intermediate phase layer was also observed at the weld interface. TEM observation revealed that the intermediate layer consisted of fine Al grains and intermetallic compound particles dispersed among the Al grains. The growth direction of the wave, the welding condition dependency of the wavelength and the amplitude of the interfacial wave were intensively investigated in order to clarify the welding mechanism of this method.
44 citations
TL;DR: In this paper, two modes of metal transfer phenomenon in FSW have been discussed with the help of three FSW techniques: a strip is welded to the plate by the process, in the second one the brass sheet is inserted perpendicular to the welding direction and in the third one the process is performed with tools having different pin lengths.
Abstract: It has been widely recognised that the fundamental mechanism of weld formation in friction stir welding (FSW) is too complex, a phenomenon to be understood completely. In the present study two modes of metal transfer phenomenon in FSW have been discussed with the help of three FSW techniques. In the first technique a strip is welded to the plate by the process, in the second one the brass sheet is inserted perpendicular to the welding direction and in the third one the process is performed with tools having different pin lengths. The results suggest a strategy to model the process particularly for predicting welding tool performance.
44 citations
Patent•
04 Jan 2006
TL;DR: The automatic argon arc welding and narrow gas submerged arc welding process for circular pipe header seam features the first horizontal and vertical welding with immobile workpiece and using automatic cold welding TIG wire until completing over one third of circle; the subsequent welding in the other two thirds of circle with automatically rotating welding roller frame; and the performing in the identical site of the annular seam assembling and the welding as discussed by the authors.
Abstract: The automatic argon arc welding and narrow gas submerged arc welding process for circular pipe header seam features the first horizontal and vertical welding with immobile workpiece and using automatic cold welding TIG wire until completing over one third of circle; the subsequent welding in the other two thirds of circle with automatically rotating welding roller frame; and the performing in the identical site of the annular seam assembling and the welding. The welding apparatus for the said technological process consists of roller device and welding frame bogie, and the welding frame bogie on some tracks parallel to roller frame tracks is movable. The present invention has the advantages of automatic operation, raised welding quality, etc.
40 citations
TL;DR: In this article, a study was conducted that characterized the critical normal loads and displacements corresponding to the transition from mixed fretting wear to gross slip in Ti6Al4V interfaces at room temperature and 450°C (842°F).
39 citations
TL;DR: In this article, a very thin silicon interlayer was used to improve the DLC adherence to the Ti6Al4V substrates, and a new system was developed to measure the friction coefficient in micro-scale in order to evaluate the friction value between highly texturized surfaces.
Abstract: This paper reports on research results from on-going studies in cold welding prevention for space applications. DLC film was tested as a protective coating on devices with texturized Ti6Al4V surfaces to prevent cold welding under conditions of high pressure in a high vacuum environment. Texturized Ti6Al4V surfaces are necessary for the mechanical engagement of movable parts in satellite devices. This kind of application requires very high adherence between the substrate and the film. In this study, the DLC depositions were performed either on smooth or on laser textured Ti6Al4V surfaces. Smooth surfaces were used to measure the friction coefficient on a nanometric scale and the textured surfaces were used to test mechanical engagement. A very thin silicon interlayer was used to improve the DLC adherence to the Ti6Al4V substrates. Both silicon and DLC films were prepared by RF magnetron sputtering with argon as the buffer gas and with an additional DC bias. Raman scattering spectroscopy was used to analyze the existence of sp 2 and sp 3 chemical bonds of DLC films and the nature of silicon structures in the silicon interlayer. The morphology and roughness were evaluated by SEM and AFM; the LFM was used to measure the friction coefficient in nanoscale and, the micro-indentation technique was used for evaluating film hardness. A new system was developed to measure the friction coefficient in microscale in order to measure the friction value between highly texturized surfaces. This paper presents an in-depth description of the testing process and the results of the cold welding prevention test of textured DLC surfaces in a high vacuum environment.
Patent•
16 Feb 2006TL;DR: In this paper, an object to reduce residual stress in a tensile direction of a weld on the inner side in contact with reactor water of austenitic stainless steel piping, and to change the residual stress into compressive stress, to reduce stress corrosive cracking is presented.
Abstract: The present invention has an object to reduce residual stress in a tensile direction of a weld on the inner side in contact with reactor water of austenitic stainless steel piping, and to change the residual stress into compressive stress, to reduce stress corrosive cracking. The present invention provides a welding process for stainless steel piping of laminating two types of welding wire made of different materials in a groove of austenitic stainless steel piping, including at least one of a first layer penetration welding step of performing a predetermined back bead width on the back side of the groove bottom and a tack welding step, a first lamination welding step of lamination welding of austenitic stainless steel wire from the bottom to the top of the groove, and a second lamination welding step of lamination welding of nickel-base alloy wire to a final layer at the top of the groove.
Patent•
19 Apr 2006TL;DR: In this article, a method for welding a gamma-prime precipitation strengthened alloy component is described, where the welding process includes preheating the alloy component to minimize the difference in contraction between the weld deposit and the substrate portion of the component during solidification and cooling.
Abstract: A method for welding a gamma-prime precipitation strengthened alloy component. In one aspect the welding process includes preheating the alloy component to minimize the difference in contraction between the weld deposit and the substrate portion of the component during solidification and cooling. The component having a weld that is substantially free of solidification cracking.
TL;DR: In this paper, the influence of welding current shape on weld strength of resistance spot welds of zinc-coated mild steel sheets was analyzed at different levels of the electrode wear, and the results showed that welding current with high peak values implies higher weld strength.
Abstract: The present paper presents the influence of welding current shape on weld strength of resistance spot welds of zinc coated mild steel sheets. The influence is analysed at different levels of the electrode wear. Welding currents with different peak values and different RMS (root mean square) values were used in the experiment. The results show that welding current with high peak values implies higher weld strength.
TL;DR: In this paper, the optimum processing conditions for joining thin sheet materials (1-3.2mm) of commercial purity titanium and Ti-6%Al-4%V by electron beam welding were determined by using single-and double-pass melting sequences.
Abstract: The optimum processing conditions for joining thin sheet materials (1–3.2 mm) of commercial purity titanium and Ti-6%Al-4%V by electron beam welding were determined by using single- and double-pass melting sequences. For commercial purity titanium weldments, the tensile properties were observed to be similar to the parent material and independent of the sheet thickness and the welding procedure. However, for Ti-6%Al-4%V, the processing conditions during welding were observed to change the characteristics of the alpha lamellae spacing and plate thickness, which in turn influenced the properties. Hence, for joining alpha-beta titanium alloys with use of electron beam welding, the definition of critical processing conditions enables optimization of the structure-property characteristics of the joint.
TL;DR: In this paper, the effects of the roller pressure, laser beam scanning speed and irradiation position on the tensile shear and peel strength of welded joints were investigated, and it was revealed that prevention and suppression of oxidation during welding was extremely important to the production of a sound joint with good mechanical properties.
Abstract: This study was performed to obtain fundamental knowledge concerning the development of laser pressure welding technology for the joining of dissimilar metals. Laser pressure welding of Al alloy A6061 and low C steel SPCC sheets was carried out to investigate the effects of the roller pressure, laser beam scanning speed and irradiation position on the tensile shear and peel strength of welded joints. The interfaces of the joints were observed and analysed by SEM and EDX, and the formation phases on the peeled surfaces were identified with XRD. It was revealed that prevention and suppression of oxidation during welding was extremely important to the production of a sound joint with good mechanical properties. The highest tensile strength and the highest peel strength of joints were obtained at a laser power of 1·8 kW, laser scanning speed of 30 Hz, laser irradiation position at the centreline, roller pressure of more than 245 MPa and welding speed of 0·5 m min−1 in an Ar atmosphere. The fracture occ...
TL;DR: In this article, the authors describe how laser spot welding and SHADOW (stepless high speed accurate and discrete one pulse welding) can be used to minimize degradation of the polymer while making fusion welds in the metal layers.
Abstract: Increasing interest has been expressed in the application of hybrid metal/polymer materials for automotive applications, both to reduce weight and to improve performance. To date, the only joining methods available are mechanical fastening and adhesive bonding, both requiring an overlapping joint configuration to generate sufficient bond strength. This article describes how laser spot-welding and SHADOW™ (stepless high speed accurate and discrete one pulse welding) welding can be used to minimize degradation of the polymer while making fusion welds in the metal layers. The thickness of the external layers in metal polymer laminates is approximately 0.25 mm. Laser spot welds on such thin materials are very susceptible to cracking due to high cooling rates causing large stresses. These high cooling rates are necessary to avoid excessive thermal degradation of the central polymer layer. This article addresses a technique to provide such high cooling rates while preventing cracking in AA5182 thin sheet during...
TL;DR: In this article, the possibility of welding these zinc coated steel sheets in an edge lap configuration without present gap is presented, where the zinc vapor between the sheets has an alternative escape route other than through the weld pool and it is shown that the amount of spatter can be controlled when using such a joint configuration.
Abstract: Ever increasing amounts of zinc coated sheet steel are being applied in the automotive industry. At present, the main joining method used for this application is resistance spot welding. In many automotive applications there are opportunities for replacing this technique by laser welding. During the assembly of these sheets major problems arise when welding in overlap configuration as result of the low boiling temperature of zinc in comparison to the melting temperature of steel. This results in pores and/or blowholes in the weld due to instabilities during welding. In this article research is presented which shows the possibilities of welding these zinc coated steel sheets in an edge lap configuration without present gap. In this configuration the zinc vapor between the sheets has an alternative escape route other than through the weld pool and it is shown that the amount of spatter can be controlled when using such a joint configuration.
TL;DR: In this article, Dubois et al. reported a vacuum or space related effect, referred to as "cold welding" or "cold sticking", for bulk quasicrystal (J.M. Dubois, 1990) versus different kinds of counterparts (steel, aluminium, titanium, hard metals).
Abstract: This paper reports a vacuum or space related effect, which is referred to as “cold welding”, “adhesion” or “sticking”. This effect is studied for bulk quasicrystal (J.M. Dubois, Useful Quasicrystals (World Scientific, Singapore, 2005)) versus different kinds of counterparts (steel, aluminium, titanium, hard metals). Full series of samples, prepared either by crystal-pulling techniques (single crystals) or by sintering (multi-grain samples) were analysed by fretting tests. Four alloy systems were investigated: Al–Pd–Mn, Al–Cr–Fe–B, Al–Cu–B and Al–Cu–Fe–B, with different crystallographic structures and nominal compositions. These materials, especially icosahedral phases, exhibit the absence of cold-welding in vacuum versus certain steels.
TL;DR: In this paper, the authors present a method for joining low-carbon steels to aluminium alloys using a laser roll welding method, which they call LRTW, and they describe the welding process of low carbon steels.
Abstract: (2006). Laser roll welding for joining of low-carbon steels to aluminium alloys. Welding International: Vol. 20, No. 6, pp. 446-456.
TL;DR: In this article, a comprehensive structural-thermoelectric model for single-sided spot welding (SSSW) is presented. But the model is limited to the case of closed tubular parts.
Abstract: As a new kind of lightweight structure, hydroformed tubes are now widely used in vehicle bodies. The single sided spot welding (SSSW) is a variation of resistance welding used in joining hydroformed closed tubular parts and vehicle structures. During the process of SSSW, large deformation and complex contact status of the workpieces occur because there is no inside support. The time variation of the contact region and pressure distribution changes the flow paths for electric current timely and brings a fierce shunting at the position far away from the axis line, which prevents the heat concentration at the faying surface of workpieces. The characteristics of SSSW different from those of classical resistance welding mentioned above make it difficult to determine rational welding processing parameters for SSSW. In the present paper, a comprehensive structural–thermoelectric model is established. Using the incrementally coupled analysis of finite element analysis, the electrical, thermal and mechanic...
TL;DR: In this article, the contact welding phenomenon observed at automotive relays at switch-off of a dc motor load during startup was investigated, where contact welding occurred during the first operation and was caused by anodic arcs shorter than 80 mus at breaking inrush currents of up to 85 A. The switching performance of the type of relay investigated could be correlated with the parameters: over-travel, release time, and the break current.
Abstract: The contact welding phenomenon observed at automotive relays at switch-off of a dc motor load during startup was investigated. Contact welding occurred during the first operation and was caused by anodic arcs shorter than 80 mus at breaking inrush currents of up to 85 A. The switching performance of the type of relay investigated could be correlated with the parameters: over-travel, release time, and the break current
TL;DR: In this article, the temperature criterion of laser welding for joining of aluminum alloy and low-carbon steel is discussed based on the experimental results, and a novel joining process is proposed.
Abstract: Aluminum alloy and low-carbon steel are dissimilar metals. In order to obtain a reciprocal comprehensive property in a joint component of aluminum alloy and low-carbon steel, laser welding was used as a novel joining process. Based on the experimental results, the temperature criterion of laser welding for joining of aluminum alloy and low-carbon steel is discussed in this paper.
Patent•
08 Jun 2006TL;DR: In this paper, a method of welding includes moving a welding torch with respect to a workpiece joint to be welded, where a first welding wire is fed through a welding wire guide defining a first-weathering wire orientation and a second-welding wire orientation that is divergent and non-coplanar.
Abstract: A welding torch includes a nozzle with a first welding wire guide configured to orient a first welding wire in a first welding wire orientation, and a second welding wire guide configured to orient a second welding wire in a second welding wire orientation that is non-coplanar and divergent with respect to the first welding wire orientation. A method of welding includes moving a welding torch with respect to a workpiece joint to be welded. During moving the welding torch, a first welding wire is fed through a first welding wire guide defining a first welding wire orientation and a second welding wire is fed through a second welding wire guide defining a second welding wire orientation that is divergent and non-coplanar with respect to the first welding wire orientation.
Patent•
24 Aug 2006TL;DR: In this paper, a friction stir welding method is used to form a mechanical interlocking structure at an interface between the substrate and the friction-stir welding device, where a friction- stir welding device is moved through a plurality of points that form an essentially conical shape as the device engages substrates to be welded.
Abstract: A friction stir welding method where a friction stir welding device is moved through a plurality of points that form an essentially conical shape as the device engages substrates to be welded to form a mechanical interlocking structure at an interface between the substrates.
Patent•
22 Mar 2006
TL;DR: In this article, a friction stir welding method with which a weld joint of high joint strength is obtained by making a joint boundary greater in friction-stir welding of different kinds of metallic materials, and to provide a friction- stir welding member is provided.
Abstract: PROBLEM TO BE SOLVED: To provide a friction stir welding method with which a weld joint of high joint strength is obtained by making a joint boundary greater in friction stir welding of different kinds of metallic materials, and to provide a friction stir welding member. SOLUTION: In the friction stir welding method, in the friction stir welding of the different kinds of metallic materials, a low melting point plated steel sheet 30 as the metallic material of a high melting point has a plating layer 30a of the melting point lower than the melting point of an aluminum alloy as the metallic material of the low melting point. The plating layer 30a is diffused by the plastic flow in a plastic fluid area 20a generated in the aluminum alloy during friction stir welding to diffuse the plating layer 30a, and the steel sheet newly-formed surface 30 of the low melting point steel sheet 30 is exposed and solid phase joining of the surface to the aluminum alloy 20 is performed to obtain the weld joint of the high joint strength. The friction stir welding member is also provided. COPYRIGHT: (C)2008,JPO&INPIT
Patent•
07 Nov 2006
TL;DR: In this article, a laser beam welding apparatus is provided with a welding head, and the welding head is movable in the direction of an arrow A to reduce the surface roughness of a weld bead.
Abstract: PROBLEM TO BE SOLVED: To provide a laser beam welding apparatus and a laser beam welding method capable of reducing the surface roughness of a weld bead. SOLUTION: The laser beam welding apparatus is provided with a welding head 1. The welding head 1 applies the first laser beam L1 to a workpiece W to be welded to form a molten pool M, and applies the second laser beam L2 to the molten pool M. By applying the second laser beam L2, the molten pool M which is being solidified after the forming can be re-melted. Since the quantity of the second laser beam L2 is smaller than that of the first laser beam, only a portion relatively close to the surface out of the molten pool M can be re-melted. Accordingly, since the welding head 1 is movable in the direction of an arrow A, the surface shape of the molten pool M can be continuously trimmed without affecting a depth direction. Thus, a weld bead having a smooth surface can be formed. COPYRIGHT: (C)2008,JPO&INPIT
Patent•
19 Dec 2006
TL;DR: In this article, a fiber laser with a power of 100 watts to 10 kilowatts is used for the laser welding/laser point welding, and the laser spotwelds are statistically or regularly distributed over the adhesive surfaces or attached at the places of the largest load.
Abstract: The joining of lightweight components by sticking for use in an automotive industry, a machine- and an aircraft construction, comprises applying inorganic and/or organic adhesives on surfaces to be joined and joining the surfaces. Immediately or after the application of the adhesives and the joining of the components, the sticking/joining surface is fixed through individual welding point and/or welded joint produced by means of laser welding, or is spot welded through several welding points and/or welded joints produced by means of remote laser. The joining of lightweight components by sticking for use in an automotive industry, a machine- and an aircraft construction, comprises applying inorganic and/or organic adhesives on surfaces to be joined and joining the surfaces. Immediately or after the application of the adhesives and the joining of the components, the sticking/joining surface is fixed through individual welding point and/or welded joint produced by means of laser welding, or is spot welded through several welding points and/or welded joints produced by means of remote laser. The hardening of the adhesive is continued and completed during the procedure of the cathode-dip lacquering or similar processes. The hardening of the adhesive takes place during the welding process or after the fusing via the heat entry of the laser. A fiber laser with a power of 100 watts to 10 kilowatts is used for the laser welding/laser point welding. For fixing of the lightweight components, the laser spotwelds are statistically or regularly distributed over the adhesive surfaces or attached at the places of the largest load. Load-adapted welding seam geometry is produced by means of remote welding.
TL;DR: In this paper, a hybrid bifocal laser welding system consisting of an Nd:YAG and a high power diode laser (HPDL) was evaluated for extruded aluminum.
Abstract: This paper renders research into the fundamentals governing the melt pool dynamics of a hybrid bifocal laser welding system consisting of an Nd:YAG and a high power diode laser (HPDL). The resulting superposition of keyhole by heat conduction mode welding is assayed for extruded aluminum. In particular the diffusion of the surface oxygen layer is considered. By comparing the results attainable by bifocal laser hybrid welding to the constituent laser processes synergetic effects of the laser hybrid can be demonstrated. These are namely the doubling of the welding speed from 2.0 min-1 to 4.0 m min-1, the reduction of the roughness of the weld surface from 60 om to approximately 10 om and an increase in energy transfer efficiency. The experimental investigations verifying these synergies are outlined and discussed.
TL;DR: In this article, it was shown that bead-on-plate friction stir welding (FSW) welds performed on alloy, which in fusion welding is susceptible to liquation cracking, were crack free.
Abstract: One of the “show stoppers” in fusion welding of highly alloyed aerospace aluminium alloys is their susceptibility for liquation cracking in the weld heat-affected zone. Liquation cracking is a microscopic intergranular discontinuity, which occurs under the effect of welding thermal cycle and in the presence of stresses involved with the welding process. These intergranular discontinuities are often observed in welding of thick plates and extrusions, which usually have relatively coarse elongated grains, that are generally oriented parallel to each other. Friction Stir Welding (FSW) is a low temperature non- fusion process, which produces very fine equiaxed grain structure in the weld nugget for majority of Al-alloys. It was found that bead-onplate FS welds performed on alloy, which in fusion welding is susceptible to liquation cracking, were crack free. It was therefore proposed to use FSW for grain refining of the parent material by putting a number of overlapping FS welds onto the edges of both parent plates prior to joining by fusion welding. Experimentation has shown that there was no liquation cracking after the final weld was performed. This novel welding method has been successfully proven for Electron Beam Welding (EBW) of various Al-alloys including joining of dissimilar materials. The details of experiments as well as welded coupons test results are presented.