Course Code: PI-415

SEMINAR
Department of Mechanical Engineering

Non-Conventional Joining
Processes
Presentation by:
Kretika Arora

B. Tech, 4th Year,

Roll No. 11610752
Production and Industrial Engg.
Department of Mechanical Engg
NIT Kurukshetra
 INTRODUCTION

Joining:
• Brings two similar or dissimilar materials together to form
product continuity
• Combines advantages of multi-materials
• Provides flexibility and increases functionality of large
number of industrial products

• Wide range of applications: Aerospace, Automobile,

Armoury, etc.
 INTRODUCTION
TYPES OF JOINTS:
1.Easily dissembled
2.Re-assembling possible
• Mechanical 3.Doesn’t lose
TEMPORARY Fastening shape/properties on
JOINTS • Screw, Nuts and dissembling.
Bolts, Studs

1.Dismantling without
• Welding
rupture is impossible
PERMANENT • Adhesive Bonding
2.High strength
JOINTS • Rivet Joints
3.Leak-proof joint
 INTRODUCTION
Example/Application:

Fig. Welding/Brazing in Bikes Fig. Rivet in huge structures

Fig. FSW in Aerospace/ HS Trains Fig. Fastener in Boilers

 JOINING/ASSEMBLY TECHNIQUES:
Arc Metal Welding
Joining Techniques

Gas Welding
Conventional
Soldering
Non-conventional
Brazing

LBW, EBW, USW,

Adhesive Bonding Explosion Welding
Friction-Stir Welding
NON-CONVENTIONAL TECHNIQUES
$$. WHY??
The conventional techniques of joining posed the following
limitations:
1. Low Weld-ability of some materials e.g. Al 5xxx series
2. Large HAZ affects base properties of metal
3. Limited scope of joining of dissimilar material
4. Warping of sections due to uneven Heat Transfer
5. Change in Metallurgical properties
6. Issues/Defects arising out of solidification
7. Dis-assembly isn’t possible

NECESSITY IS THE MOTHER OF INVENTION!

NON-CONVENTIONAL TECHNIQUE
1. FRICTION STIR WELDING

Solid-state welding process:

• The welding of materials doesn’t take place post-melting.
• A non-consumable rotating tool creates heat and pressure
to build a softened zone.
• As tool traverses, it mechanically intermixes the two
materials, hence forming joints.
 FRICTION STIR WELDING
OPERATING PRINCIPLE

A rotating cylindrical tool with a profiled

probe is fed into a butt-joint, until the
shoulder, touches the surface of the work-
pieces.

Frictional heat is generated between the

wear-resistant tool and the work pieces.
This heat, along with heat generated from
mechanical intermixing cause the stirred FSW
materials to soften without melting.
 FRICTION STIR WELDING
OPERATING PRINCIPLE

As the tool moves forward, a

special profile on the probe
forces plasticized material from
the leading face to the rear,
where the high forces assist in a
forged consolidation of the weld.
FSW: Operating Principle
 FRICTION STIR WELDING
IMPORTANT WELDING PARAMETERS

1. Tool Design
A good tool improves:
1. Welding quality and strength
2. Depth of plates which can be welded
3. Maximum rotation speed of the tool

Desirable Properties:
1. Strong, tough & low-wear rate
2. Oxidation resistance
3. Low thermal conductivity
 FRICTION STIR WELDING
IMPORTANT WELDING PARAMETERS

The shoulders have concave faces to stop removed material

from escaping and maintaining pressure.

Example: Hot worked Tool Steel AISI H13

2. Tool Rotation and Traverse Speed

Tool speeds to be considered:
1. Rotation about axis
2. Transverse motion along work-piece
 FRICTION STIR WELDING
IMPORTANT WELDING PARAMETERS
The heat input should just be sufficient enough to start plastic
deformation of the materials.

What if…
1. Rotation speed is too high and Transverse too low?
a. A hotter weld will form
b. The materials may liquefy causing defects
c. Affects base properties of material

2. Rotation speed is too low and Transverse too high?

a. Voids may be present
b. The tool might break
 NON-CONVENTIONAL TECHNIQUE
2. ADHESIVE BONDING
• This joining technique is an effective replacement for
conventional techniques
• This technique is highly beneficial for joining of components
on which the applications of conventional joining techniques
are difficult, such as aluminium.
•

Joining of Even Good

Corrosion
dissimilar distribution damping
resistance
materials of load property
 NON-CONVENTIONAL TECHNIQUE
2. ADHESIVE BONDING

Process Principle:

• Adhesive bond forms when due to adhesion-cohesion forces

acting in adhesive substrate system
• Adhesion forces arise out of van-der-waals force, covalent
bond, ionic bond etc.
• Bond may either form on the adhesive-substrate interface or
within the volume of substrate (in case of diffusion).
• Substrates also cling together due to micromechanical
bonding.
 NON-CONVENTIONAL TECHNIQUE
2. ADHESIVE BONDING
WORKING:

Aluminium Strips
Aluminium Strips Adhesive

Surface Preparation

Fixture

CURING LAP JOINT

 NON-CONVENTIONAL TECHNIQUE
2. ADHESIVE BONDING

Process Parameters:
General Graphical
Trend
• Curing Time
• Surface Roughness R
• Adhesive Application Technique E
S
• Overlap Length U
• Overlap Area** L
• Width (Volume/Area) of adhesive line T

PARAMETERS
NON-CONVENTIONAL TECHNIQUE
3. EXPLOSION WELDING

EXPLOSIVES RUBBER PLATE

FLYER PLATE

SOD
BASE PLATE

Figure. Set-up of Explosion Welding

Major Application: Cladding
NON-CONVENTIONAL TECHNIQUE
4. Electron Beam Welding
• A beam of electrons is used.
• Cathode (W) produces electrons
• Magnetic focussing lens helps focus
the e-beam to welding area.
• Setup has to be kept in vacuum
• X-rays are produced, so the setup is
kept in lead-lined box
• Welding speed is high
• Depth of penetration is high
• HAZ is low
• Metal with high MP can be weld
easily
 CONCLUSION
The Non-Conventional Techniques have been able to broadly
conquer over many of the limitations posed by the
Conventional Techniques

• Low Weld-ability: Such materials can be joined using

Adhesive Bonding technique
• Large HAZ: Adhesive Bonding, EBW overcomes this
issue effectively
• Dissimilar materials: Adhesive Bonding
• Dis-assembly possibility: Field of active research to
produce adhesives which can be re-used.