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How to Weld Dissimilar Aluminum

Friction welding is an effective means of welding dissimilar materials, such as aluminum alloys, with very different melting temperatures and mechanical properties. Friction welding, used in a broad range of aviation and automotive applications, involves generating friction between a moving workpiece and a stationary component, until the workpiece and component reach the necessary temperature and material deformation. At that point, a force is exerted on the two components, to facilitate the formation of a solid-phase bond between the two.

Friction welding tool

Instructions

- 1
  Attach one of the pieces of aluminum to the motor-driven unit of the friction welding tool. Rotate the piece at a predetermined constant speed.
- 2
  Move together the two pieces of aluminum to be welded. Plunge the pin tip of the spinning cylindrical tool into the piece of aluminum not attached to the motor. The pin tip applies a friction welding force.
- 3
  Allow the two surfaces of aluminum to rub together for a predetermined time. Discontinue the driving force.
- 4
  Maintain, or increase, the friction welding force for a predetermined amount of time after the driving force ceases.

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