Solid‐State Welding

Processes
 Solid‐State Welding Processes
 Solid‐state welding refers to a family of processes that produce welds without the requirement
for molten metal.
 Solid‐state welding theory emphasizes that the driving force for two pieces of metal to
spontaneously weld to each other exists if the barriers to welding can be eliminated.
 All solid‐state welding processes use some combination of heat, pressure, and time to overcome
the barriers. Approaches include Friction, Resistance, Diffusion, Explosion etc.
 Solid‐state welding processes also do not require filler materials, and in some cases, can be quite
effective at welding dissimilar metals.
 Since there is no melting, there is no chance for the formation of defects that are only associated
with fusion welding processes such as porosity, slag inclusions, and solidification cracking.
Solid‐State Welding Theory
Roll Bonding Theory

Cladding

Roll Bonding of the US Quarter

Production of Bimetallic Strips

 Ultrasonic Welding (USW)
Normal force

• Frequency ~10-75kHz

• Shearing Stresses

• Joining of Dissimilar metal

Shearing force • Joining of Plastics

• Lap joint for sheets, foils, wire

Friction Welding

• Frictional heat

• Rotational symmetry

• Thermal Conductivity

• Rotational speed & Pressure

• Flash Removal
Friction Stir Welding FSW

Stages of FSW

• Plunging

• Welding

• Retracing
Friction Stir Welding FSW
 Resistance Welding (RW)
Resistance welding uses a combination of heat and pressure to accomplish coalescence
Heat generated by electrical resistance to current flow at junction to be welded
(J = I2Rt) heating
 Resistance Welding (RW)

Resistance Seam Welding Resistance Projection Welding

Resistance Welding (RW)
Resistance Welding (RW)

Advantages:

 No filler metal required

 High production rates possible

 Mechanization and automation

 Lower operator skill level

 Good repeatability and reliability

 Disadvantages:

 High initial equipment cost

 Limited to lap joints for most RW

Explosion Welding
Explosion Welding
Diffusion Bonding