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Aluminium alloys are often used due to their high strength-to-weight ratio, corrosion resistance, low cost, high thermal and electrical conductivity.There are a variety of techniques to join aluminium including mechanical fasteners, welding, adhesive bonding, brazing, soldering and friction stir welding (FSW), etc. Various techniques are used based on the cost and strength required for the joint.
Ultrasonic welding is an industrial process whereby high-frequency ultrasonic acoustic vibrations are locally applied to work pieces being held together under pressure to create a solid-state weld. It is commonly used for plastics and metals , and especially for joining dissimilar materials .
Exothermic welding, also known as exothermic bonding, thermite welding (TW), [1] and thermit welding, [1] is a welding process that employs molten metal to permanently join the conductors. The process employs an exothermic reaction of a thermite composition to heat the metal, and requires no external source of heat or current.
Diffusion bonding or diffusion welding is a solid-state welding technique used in metalworking, capable of joining similar and dissimilar metals. It operates on the principle of solid-state diffusion, wherein the atoms of two solid, metallic surfaces intersperse themselves over time.
Thermocompression bonding describes a wafer bonding technique and is also referred to as diffusion bonding, pressure joining, thermocompression welding or solid-state welding. Two metals, e.g. gold-gold (Au), are brought into atomic contact applying force and heat simultaneously. [1]
Cladding is the bonding together of dissimilar metals. It is different from fusion welding or gluing as a method to fasten the metals together. Cladding is often achieved by extruding two metals through a die as well as pressing or rolling sheets together under high pressure. The United States Mint uses cladding to manufacture coins from ...
Rotary friction welding is widely implemented across the manufacturing sector and has been used for numerous applications, [17] [18] [19] including: Parts in gas turbine such as: turbine shafts, turbine discs, compressor drums, [20]
Flash welding is also used in the metal building industry to increase the length of the angle iron used to fabricate joists. [1] The aluminum industry uses flash welding to join aluminum, steel, and copper in various current-carrying conductors called busbars. The steel is used for strength, the copper is used for conductivity, and the aluminum ...
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