brief presentation that demonstrates some solid state welding methods and their application, in addtion to its pros and cons. presented in Advanced - ADVANCED WELDING TECHNOLOGIES - course held at jazan university by Dr. Jaber Al awadi

1. SOLID STATE WELDING
Around us
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Presented by Abdulaziz & Firas

2. Assembly of Ariane 5 main motor thrust frame
from 12 integrally machined, blade stiffened, flat
panels
Ariane 5
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3. Tuesday, February 7, 2023 ADVANCED WELDING TECHNOLOGIES 3

4. Tuesday, February 7, 2023 ADVANCED WELDING TECHNOLOGIES 4

5. Goal
To Know the applications of solid
state welding and its challenges
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2023 ADVANCED WELDING TECHNOLOGIES 5

6. Terminology
Welding Solid state
welding
Fusion
welding
Melting
temperature
Weld
Defect
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7. Comparison
Advantages
Free
microstructure
defects
Good weld
Mechanical
properties
Non –
consumable
join dissimilar
metals
disadvantage
Expensive
equipment
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8. Price Ranges
Fusion welding Solid state welding
39 000 . 00 SAR
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9. Classification of Solid state welding
Roll welding (ROW) Forge welding (FOW)
Friction welding
(FRW)
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10. Classification of Solid state welding
Friction stir welding
(FSW)
Diffusion welding
(DFW)
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11. More details?
How can we implement them?
What are their strength and weakness points?
Where do they stand in the world?
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12. Forge welding (FOW)
• heating two pieces of metal
before hammering, pressing or
rolling them together to create a
joint.
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13. Forge welding (FOW)
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Advantages Disadvantages
Simple and easy Only small objects can be
welded
Inexpensive Require high skill
weld similar and
dissimilar metals
High welding defects
Weld joint similar to base
metal
Small production
Mostly suitable for iron
and steel

14. Forge welding (FOW)
• Application
• Sword making
• manufacture gates, prison cells
• cookware
• shotgun barrels
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15. Friction welding (FRW)
• welding in which the heat is
produced by rotating one
component against the other
under compression.
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16. Friction welding (FRW)
Friction weldable material
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(i) Aluminium and its alloys (xii) Zirconium alloys
(ii) Nickel alloys (xiii) Alloy steel to carbon steel
(iii) Brass and bronze (xiv) Copper to carbon steels
(iv) Alloy steels (xv) Super alloys to carbon steels
(v) Magnesium alloys (xvi) Stainless steel to carbon steels
(vi) Carbon steels (xvii) Sintered steels to carbon steels
(vii) Stainless steel (xviii) Aluminium to stainless steels
(viii) Tool steel (xix) Copper to aluminium, etc.
(ix) Tantalum
(x) Titanium alloys
(xi) Tungsten

17. Friction welding (FRW)
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Advantages Disadvantages
Low power requirements restricted to flat and
angular welds
Containment and oxide
are thrown off
Flash material
Heat is localized high forces
Easily automated requires
a heavy rigid machine

18. Friction welding (FRW)
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Heat Desired temperature Axial force

19. Friction welding (FRW)
• Application
• joining steels, super alloys,
non ferrous metals
• Tubes
• Shafts
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20. Friction stir welding (FSW)
• Working process
• Heat is generated by friction
between the rotating tool and
the workpiece material, which
leads to a softened region near
the FSW tool
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21. Friction stir welding (FSW)
• Advantage and disadvantage
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Advantages Disadvantages
No need for filler wire to
create heat.
special fixture
arrangement required
Reduced distortion and
shrinkage.
FSW cannot make filler
joints.
very consistent and
repeatable process
High initial cost.
requires no cooling Non Forgeable material
cannot be weld.
Stronger product as
compared to conventional
welding
No need for filler wire to
create heat.

22. Friction stir welding (FSW)
• Application
• welding wings, fuel tanks, aircraft
structure.
• marine industries for structure
work.
• weld wheel rims, chassis, fuel
tanks.
• joining pipelines, heat exchanger
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23. Diffusion welding (DFW)
• Working process
• operates on the principle of
solid-state diffusion, wherein the
atoms of two solid, metallic
surfaces intersperse themselves
over time.
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24. Diffusion welding (DFW)
• Advantage and disadvantage
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Advantages Disadvantages
good dimension tolerance High initial or setup cost
Good weld mechanical
properties
time consuming process
produces clean joint Difficult Surface
preparations
Can join similar and
dissimilar material
not suitable for mass
production

25. Diffusion welding (DFW)
• Application
• weld refectory materials
• weld titanium, zirconium and
beryllium metals
• weld nickel alloy
• weld dissimilar metals like Cu to Ti
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Diffusion welding machine

26. Roll welding (ROW)
• process
• a process in which two or more
sheets or plates are stacked
together and then passed
through the rolls until sufficient
deformation has occurred to
produce solid-state welds.
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27. Roll welding (ROW)
• Advantage and disadvantage
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Advantages Disadvantages
High production rate limited to small
reductions
Good finish limited to only a few
shapes
good dimensional
accuracy
High cost of equipment

28. Roll welding (ROW)
• Application
• Making hollow seamless tubes.
• Roofing panels, partition beams,
railroads.
• Used in automotive industries.
• Steel sheets, plates .
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29. Conclusion
• Solid state welding is much more defect free than fusion welding, but
this feature comes at a high cost, non the less solid-state welding is
used when high weld quality is needed or when simply when you can
use fusion ex. (aluminum welding).
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30. Resources
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[1]
https://www.slideshare.net/Abdul
lahMansoor1/solid-state-welding-
61957800?from_search=0
[2] UNIT III SOLID STATE WELDING
PROCESSES (summary found
online)

31. Thank you
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