Solid State Welding

Processes
Presented By:
Raju Panchal(13BME061)

Introduction

It is a welding process, in which two work pieces are joined under a pressure
providing an intimate contact between them and at a temp. essentially below
the melting point of the parent material.

Bonding is a result of diffusion of the interface atoms.

Physical Principles

Solid State Welding Processes

Diffusion welding

Explosion welding

Friction welding

Friction- stir welding

Forge welding

Cold welding

Roll welding

Hot pressure welding

Ultrasonic welding, etc.

Explosion Welding

Explosion welding was developed relatively

recently, decades after world war-II.

This process is most commonly utilized to clad

carbon steel with the corrosion-resistant material
e.g. stainless steel, nickel alloy, titanium,
zirconium, etc.

SSW process in which rapid coalescence of two metallic surfaces is caused by

the energy of a detonated explosive.

The process is quite dangerous and should be performed under some experts
in specially designed chambers.

Common Explosives used

Advantages and Disadvantages

ADVANTAGES

Dissimilar material joining is

possible through this process.
E.g., Al to steel, Cu to steel,
Tungsten to steel, etc.

Brittle materials( Low impact

toughness) can not be welded.

Extensive knowledge of explosives

is needed before the procedure may
be attempted safely.

The geometries must be simple.

No filler metal used.

No external heat applied.

Bonding is metallurgical,
combined with mechanical
interlocking that results from a
rippled or wavy interface
between the metals.

DISADVANTAGES

APPLICATIONS

Joining of pipes and tubes

Attaching cooling fins

Major app. In pressure vessels

Friction Welding

SSW process in which

coalescence is achieved by
frictional heat combined
with pressure.

1)

Rotating part, no contact

2)

Parts brought into contact

to generate friction heat

3)

Rotation stopped and axial

pressure applied

4)

Weld created

Advantages and Disadvantages

ADVANTAGES

DISADVANTAGES

Process yields a narrow HAZ

Can be used to join dissimilar

metals

At least one of the parts must

be rotational.

Flash must be removed (extra

operation)

Upsetting reduces the part

lengths (which must be taken
into consideration in product
design)

APPLICATIONS

Shaft and Tubular parts

Friction Stir Welding (FSW)

SSW process in which a rotating tool is fed along a joint line between two
work-pieces, generating friction heat and mechanically stirring the metal to
form the weld seam

Distinguished from FRW because heat is generated by a separate wearresistant tool rather than the parts

Butt joints in large aluminium parts in aerospace, automotive, and

shipbuilding

Friction Stir Welding

Advantages and Disadvantages of

Friction Stir Welding

Advantages

Good mechanical properties of

weld joint

Disadvantages

Avoids toxic fumes, warping,

and shielding issues

Keyhole at the end of each

weld

Little distortion or shrinkage

Non-consumable tool

Heavy duty clamping of parts is

required

Backing bar required.

Diffusion Welding (DFW)

SSW process uses heat and pressure, usually in a
controlled atmosphere, with sufficient time for diffusion
and coalescence to occur

Temperatures 0.5 Tm

The process is often conducted in vacuum in order to

keep the bonded surfaces clean from oxides and air
contaminations.

Plastic deformation at surfaces is minimal

DFW Applications

Joining of highstrength and refractory metals in aerospace and nuclear industries

Can be used to join either similar and dissimilar metals

For joining dissimilar metals, a filler layer of different metal is often sandwiched
between base metals to promote diffusion

DISADVANTES

Relatively high initial investment in equipment

The mating surfaces must be precisely fitted to each other.

The surface preparation is required prior to welding process.

Time consuming process with low productivity