Solid State Welding (SSW)

Solid State Welding (SSW)
Solid State Welding (SSW)
Coalescence of part surfaces is achieved by:
If both heat and pressure are used, heat is not enough to melt
work surfaces
Pressure alone, or
Heat and pressure
For some SSW processes, time is also a factor
No filler metal is added

Each SSW process has its own way of creating a bond at the
faying surfaces
Essential factors for a successful solid state weld are that the
two faying surfaces must be:
Very clean
In very close physical contact with each other to permit atomic bonding
Solid State Welding (Cont)
SSW Advantages over FW Processes
If no melting, then no heat affected zone, so metal

around joint retains original properties
Many SSW processes produce welded joints that bond
the entire contact interface between two parts rather
than at distinct spots or seams
Some SSW processes can be used to bond dissimilar
metals, without concerns about relative melting points,
thermal expansions, and other problems that arise in FW
What is friction stir welding (FSW), and how is it different from friction welding?
Answer. Friction stir welding (FSW) is a solid state welding process in which a rotating tool is
fed along the joint line between two workpieces, generating friction heat and mechanically
stirring the metal to form the weld seam. FSW is distinguished from conventional friction
welding (FRW) by the fact that friction heat is generated by a separate wear-resistant tool rather
than by the parts themselves.
Solid State Welding (Cont.)
Processes under SSW group
Forge welding
Cold welding
Roll welding
Hot pressure welding
Diffusion welding
Explosion welding
Friction welding
Ultrasonic welding
Solid State Welding - Forge Welding
Forge Welding
SSW process in which

components to be joined are
heated to hot working temperature
range and then forged together by
hammering or similar means
Historic significance in
development of manufacturing
technology
Process dates from about
1000 B.C., when blacksmiths
learned to weld two pieces of
metal
Solid State Welding - Cold Welding

(CW)
Cold Welding (CW)
SSW process done by applying high

pressure between clean contacting
surfaces at room temperature
Cleaning usually done by degreasing
and wire brushing immediately before
joining
No heat is applied, but deformation
raises work temperature
At least one of the metals, preferably
both, must be very ductile
Soft aluminum and copper suited
to CW
Applications: making electrical
connections
Dies
Workpiece Workpiece
Before welding
After welding
Solid State Welding - Roll Welding

(ROW)
SSW process in which pressure sufficient to cause

coalescence is applied by means of rolls, either with or
without external heat
Variation of either forge welding or cold welding, depending
on whether heating of workparts is done prior to process
If no external heat, called cold roll welding

If heat is supplied, hot roll welding
Solid State Welding - Roll Welding

(ROW)
Applications
Cladding stainless steel to mild or low alloy steel for

corrosion resistance
Bimetallic strips for measuring temperature
"Sandwich" coins for U.S mint
Solid State Welding - Diffusion Welding

(DFW)
Diffusion Welding
SSW process that uses heat

and pressure, usually in a
controlled atmosphere, with
sufficient time for diffusion and
coalescence to occur
Temperatures 0.5 Tm
Plastic deformation at surfaces
is minimal
Primary coalescence
mechanism is solid state
diffusion
Limitation: time required for
diffusion can range from
seconds to hours
Work pieces
Force
A
Schematic representation of
diffusion welding using
electrical resistance for heating
Solid State Welding - Diffusion Welding

(DFW)
DFW Applications
Joining of high-strength 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
Solid State Welding - Explosion

Welding (EXW)
Explosion Welding (EXW)
SSW process in which rapid coalescence of two metallic

surfaces is caused by the energy of a detonated
explosive
No filler metal used
No external heat applied
No diffusion occurs - time is too short
Bonding is metallurgical, combined with mechanical
interlocking that results from a rippled or wavy interface
between the metals
Commonly used to bond two dissimilar metals, in
particular to clad one metal on top of a base metal over
large areas
Solid State Welding Explosion Welding (EXW)
Figure 31.27 Explosive welding (EXW): (1) setup in the

parallel configuration, and (2) during detonation of the
explosive charge.
Solid State Welding - Friction Welding

(FRW)
SSW process in which coalescence is achieved

by frictional heat combined with pressure
When properly carried out, no melting occurs at
faying surfaces
No filler metal, flux, or shielding gases normally
used
Process yields a narrow HAZ
Can be used to join dissimilar metals
Widely used commercial process, amenable to
automation and mass production
Solid State Welding Friction Welding (FRW)
Figure 31.28 Friction welding (FRW): (1) rotating part, no contact; (2)
parts brought into contact to generate friction heat; (3) rotation
stopped and axial pressure applied; and (4) weld created.

(FRW)
1.
2.
Two Types of Friction Welding

Continuous-drive friction welding
One part is driven at constant rpm against

stationary part to cause friction heat at
interface
At proper temperature, rotation is stopped

and parts are forced together
Inertia friction welding
Rotating part is connected to flywheel,

which is brought up to required speed
Flywheel is disengaged from drive, and

parts are forced together

(FRW)
Applications:
Shafts and tubular parts
Industries: automotive, aircraft, farm equipment,
petroleum and natural gas
Limitations:
At least one of the parts must be rotational
Flash must usually be removed
Upsetting reduces the part lengths (which must be
taken into consideration in product design)

Solid State Welding (SSW)

Uploaded by

Copyright:

Available Formats

Solid State Welding (SSW)

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Solid State Welding (SSW)

Uploaded by

Copyright:

Available Formats

Solid State Welding (SSW)

Solid State Welding (SSW)

Coalescence of part surfaces is achieved by:

For some SSW processes, time is also a factor

No filler metal is added

Solid State Welding (Cont)

SSW Advantages over FW Processes

If no melting, then no heat affected zone, so metal

Solid State Welding (Cont.)

Processes under SSW group

Solid State Welding - Forge Welding

SSW process in which

Solid State Welding - Cold Welding

Cold Welding (CW)

SSW process done by applying high

Solid State Welding - Roll Welding

SSW process in which pressure sufficient to cause

If no external heat, called cold roll welding

Solid State Welding - Roll Welding

Cladding stainless steel to mild or low alloy steel for

Solid State Welding - Diffusion Welding

SSW process that uses heat

Solid State Welding - Diffusion Welding

Joining of high-strength and refractory metals in

Solid State Welding - Explosion

Explosion Welding (EXW)

SSW process in which rapid coalescence of two metallic

Solid State Welding Explosion Welding (EXW)

Figure 31.27 Explosive welding (EXW): (1) setup in the

Solid State Welding - Friction Welding

SSW process in which coalescence is achieved

Solid State Welding Friction Welding (FRW)

Solid State Welding - Friction Welding

Two Types of Friction Welding

One part is driven at constant rpm against

At proper temperature, rotation is stopped

Rotating part is connected to flywheel,

Flywheel is disengaged from drive, and

Solid State Welding - Friction Welding

You might also like