This paper aims at providing a state-of-the-art review of an increasingly important class of joining technologies called solid-state (SS) welding, as compared to more conventional fusion welding. Among many other advantages such as low heat input, SS processes are particularly suitable for dissimilar materials joining. In this paper, major SS joining technologies such as the linear and rotary friction welding (RFW), friction stir welding (FSW), ultrasonic welding, impact welding, are reviewed, as well as diffusion and roll bonding (RB). For each technology, the joining process is first depicted, followed by the process characterization, modeling and simulation, monitoring/diagnostics/ nondestructive evaluation (NDE), and ended with concluding remarks. A discussion section is provided after reviewing all the technologies on the common critical factors that affect the SS processes. Finally, the future outlook is presented.
A B S T R A C T Fatigue is one of the principle damage mechanisms in materials especially at elevated temperatures. It possesses a great influence on the material properties and the possible working life.In this work, a novel technique for the analysis of fatigue at elevated temperature is suggested. Material fundamental frequency and its drop are used as the key parameters to predict the remaining useful life of a selected shape specimen, which is operated under low-cyclic fatigue loading at elevated temperature. Experiments are performed on aluminium 1050 with two different lengths of a non-prismatic cantilever beam at room temperature, 100, 200 and 300°C, respectively. The experimental data is further transformed in to an empirical correlation that can predict specimen useful life. The error in this life prediction is less than 5%, and it reduces more once the frequency drop is increased.
Roll bonding (RB) describes solid-state manufacturing processes where cold or hot rolling of plates or sheet metal is carried out for joining similar and dissimilar materials through the principle of severe plastic deformation. This review covers the mechanics of RB processes, identifies the key process parameters, and provides a detailed discussion on their scientific and/or engineering aspects, which influence the microstructure–mechanical behavior relations of processed materials. It further evaluates the available research focused on improving the metallurgical and mechanical behavior of bonded materials such as microstructure modification, strength enhancement, local mechanical properties, and corrosion and electrical resistance evolution. Moreover, current applications and advantages, limitations of the process and developments in dissimilar material hot roll bonding technologies for producing titanium to steel and stainless steel to carbon steel ultra-thick plates are also discussed. The paper concludes by deliberating on the bonding mechanisms, engineering guidelines and process–property–structure relationships, and recommending probable areas for future research.
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