Deformation Assisted Joining

N. Bay*, L. M. Alves, C. V. Nielsen, C. M. A. Silva, P. A. F. Martins

*Corresponding author for this work

Research output: Contribution to conferenceConference abstract for conferenceResearchpeer-review

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The large variety in new materials applied in industrial production and especially in automotive industry implies severe challenges to assembly operations. Material combinations such as high strength steel to itself, aluminium to itself, aluminium and magnesium alloys to steel and metals to sandwich materials and polymers are very difficultor impossible to join by welding. This has promoted the development of alternative methods of assembly. Among these methods an important group is deformation assisted joining. The paper categorizes these methods into the following types of joining mechanisms: 1. Mechanical joining including form-fit as well as force-fit (friction based) joints, 2. Solid phase welding and 3. Fusion welding combined with plastic deformation. Subsequently, the authors present their own developments of industrial application examples on each of the three types of assembly. Examples on mechanical form-fit joining are lap and T-joints of sheet by sheet-bulk forming and joining of tubes and tubes-to sheetby plastic instability and sheet-bulk forming. Examples on mechanical force-fit joints include bi-material coins with a polymer center and a surrounding metal ring and microjoining of a copper fork to a copper wire by resistance heating. Examples on solid phase welding include cold pressure welding of: aluminium alloy to mild steel by cross shear roll bonding for automotive slide bearings and end cap to thin walled aluminium container byironing used for a liquid gas floater valve. Resistance welding of solid state joints are exemplified by projection welding of a steel flange to a tin-bronze tube for a thermostat valve , whereas combined fusion and solid state welding is obtained in automotive three sheet spot welding and projection welding of two sheets perpendicular to each other. Resistance projection welding of advanced high strength steels by introducing an intermediate donut shaped ring of mild steel and resistance spot welding of new, lightweight sandwich material with a polymer core by introducing a shunt tool to initiate the weld represent examples on fusion welding combined with plastic deformation.
Original languageEnglish
Publication date2019
Number of pages1
Publication statusPublished - 2019
Event1st International Conference on Advanced Joining Processes - Ponta Delgada, Portugal
Duration: 24 Oct 201925 Oct 2019


Conference1st International Conference on Advanced Joining Processes
CityPonta Delgada


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