MODERN JOINING

PROCESSES

SANJAY KRISHNAN C
218ME2209
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 NEED OF NEW PROCESSES

Increased use of metal – composite matrices in industries

Requirement of new techniques for joining of dissimilar materials

Lack of conventional processes which can be easily automated

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 TYPES OF JOINING PROCESSES

A. Mechanical joining methods

B. Thermal joining methods

C. Hybrid joining methods

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 A. MECHANICAL JOINING METHODS
1.CLINCHING

Fig :Clinching operation. Joining of dissimilar materials K. Martinsen S.J. Hu, B.E. Carlson

 Interlocking formed through local plastic deformation using punch and die 4
 ADVANTAGES
No extra components are required

High economic efficiency

Can be used to join dissimilar materials

‘Difficult to weld’ materials can be joined

Joining of Aluminium with High strength steel

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 2. FRICTION STIR BLIND RIVETING

Fig : Friction stir blind riveting. Joining of dissimilar materials K. Martinsen S.J. Hu, B.E. Carlson

Blind rivet is rotated at high speed

Lowered onto the upper surface

Generates frictional heat – softens the material

Rivet moves into the stack with less force 6

 ADVANTAGES

No predrilled hole is needed

Can be used to join dissimilar materials

Increased hardness due to presence of thermo – mechanical zone

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 3. SELF-PIERCING RIVETING

Fig :Self piercing riveting. Joining of dissimilar materials K. Martinsen S.J. Hu, B.E. Carlson

Specially designed cylindrical rivets are used

Rivet is pierced through top sheet

Rivet expands while joint forming

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Both sheets and rivet undergoes deformation
 ADVANTAGES
No predrilled hole is needed

Can be used to join dissimilar materials

Fast cycle time

Incorporation with resistance spot welding based assembly line

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 B.THERMAL JOINING METHODS

1. FRICTION STIR WELDING

Fig : Friction stir welding. The Welding Institute

Rotating stirring tool generates frictional heat

Tool travels along the junction

Materials get mechanically stirred and bonded 10

 ADVANTAGES

‘Difficult to weld’ materials can be joined

Joining of Aluminium alloys and other light-weight materials

Easy to automate

Materials are not melted- no change in microstructure, minimum residual stress

Environment friendly

Non consumable tool is used 11

 2. FRICTION BIT JOINING

Fig :Self piercing riveting. Joining of dissimilar materials K. Martinsen S.J. Hu, B.E. Carlson

Use a consumable tool

Rotating bit cut through top sheet

Produce frictional heat

Diffusion bond formation between bit and work piece 12

 ADVANTAGES

Joining of dissimilar materials are possible

More strength than self piercing riveted joints

Can be used to join steel sheets with higher modulus of rigidity

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 3. REDUCED PRESSURE ELECTRON BEAM
WELDING

Modification of electron beam welding

No need of large vacuum chamber

Working pressure – 1mbar

Fig : Electron gun and differentially
pumped transfer column, The Welding
Institute
Electron beam generator using differentially pumped transfer column

Establish a welding vacuum using vacuum pump 14

 ADVANTAGES

Increased tolerance to component cleanliness

High gun stand-off distance (400mm)

Reduced pumping time

No need of vacuum chamber- on site welding is possible

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 C. HYBRID JOINING METHODS
1. LASER-MIG WELDING

Combination of Laser Welding and MIG Welding

Laser vaporises the work piece metal

Creation of deep - narrow heat affected zone

MIG process provides further heat

Gap bridging by filler materials

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Fig :Laser-MIG welding . The Aluminium Automotive Manual

 ADVANTAGES

High joining rate

Low cost compared to laser welding

Low levels of distortion

Ability to add filler material-improved joint quality

High reproducibility 17
 2. RIV-BONDING

Combination of Riveting and Adhesive bonding

Adhesive is applied to one of the components

Components joined by blind riveting

Fig :Laser-MIG welding . The Aluminium Automotive Manual

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 ADVANTAGES

Continuous joint instead of point joint

Higher strength

Higher joint stiffness

Leak tight joint

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 3. WELD-BONDING

Combination of Resistance spot welding and Adhesive bonding

Paste of adhesive is applied to one component before assembly

Resistance spot welding after assembling the sheets

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 ADVANTAGES

Continuous joint instead of point joint

Better sealing

Increased load distribution

Leak tight joint

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•THANK YOU

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