Chapter 5
Welding of Dissimilar
Metals—Challenges and a Way Forward
with Friction Stir Welding
Suryakanta Sahu, Surjya Kanta Pal, Mahadev Shome,
and Prakash Srirangam
Abstract The joining of dissimilar materials is proving beneficial for several industrial applications to achieve desired properties and improve the production economy.
However, producing a satisfactory joint in between dissimilar metals is always being
a challenge due to their distinct physical and chemical properties. This chapter will
highlight those challenges, and also discuss about available welding methods for
joining of dissimilar metals. Recently, the use of metals, for example, aluminium and
magnesium, has been at the forefront in the automotive sectors because of their lightweight characteristics. These metals are being combined with steel to produce joints
that are proving to be appropriate counterparts to the existing steel-based products.
Thus, a detailed study regarding the importance, difficulties, and different welding
methods for joining dissimilar metals for automobile industries has been outlined.
Further, a case study has been presented, where aluminium-steel combination of
dissimilar metals is joined using friction stir welding.
Keywords Dissimilar metals · Welding methods · Friction stir welding ·
Mechanism of joining · Intermetallic compound
S. Sahu
Advanced Technology Development Centre, Indian Institute of Technology Kharagpur,
Kharagpur, West Bengal 721302, India
e-mail: suryakanta@iitkgp.ac.in
S. K. Pal (B)
Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, Kharagpur,
West Bengal 721302, India
e-mail: skpal@mech.iitkgp.ac.in
M. Shome
Materials Welding and Joining, R&D, TATA Steel, Jamshedpur, Jharkhand 831001, India
e-mail: mshome@tatasteel.com
P. Srirangam
Warwick Manufacturing Group, The University of Warwick, Coventry CV4 7AL, UK
e-mail: P.Srirangam@warwick.ac.uk
© Springer Nature Switzerland AG 2021
J. P. Davim (ed.), Welding Technology, Materials Forming, Machining
and Tribology, https://doi.org/10.1007/978-3-030-63986-0_5
167
Welding of Dissimilar
Metals—Challenges and a Way Forward
with Friction Stir Welding
Suryakanta Sahu, Surjya Kanta Pal, Mahadev Shome,
and Prakash Srirangam
Abstract The joining of dissimilar materials is proving beneficial for several industrial applications to achieve desired properties and improve the production economy.
However, producing a satisfactory joint in between dissimilar metals is always being
a challenge due to their distinct physical and chemical properties. This chapter will
highlight those challenges, and also discuss about available welding methods for
joining of dissimilar metals. Recently, the use of metals, for example, aluminium and
magnesium, has been at the forefront in the automotive sectors because of their lightweight characteristics. These metals are being combined with steel to produce joints
that are proving to be appropriate counterparts to the existing steel-based products.
Thus, a detailed study regarding the importance, difficulties, and different welding
methods for joining dissimilar metals for automobile industries has been outlined.
Further, a case study has been presented, where aluminium-steel combination of
dissimilar metals is joined using friction stir welding.
Keywords Dissimilar metals · Welding methods · Friction stir welding ·
Mechanism of joining · Intermetallic compound
S. Sahu
Advanced Technology Development Centre, Indian Institute of Technology Kharagpur,
Kharagpur, West Bengal 721302, India
e-mail: suryakanta@iitkgp.ac.in
S. K. Pal (B)
Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, Kharagpur,
West Bengal 721302, India
e-mail: skpal@mech.iitkgp.ac.in
M. Shome
Materials Welding and Joining, R&D, TATA Steel, Jamshedpur, Jharkhand 831001, India
e-mail: mshome@tatasteel.com
P. Srirangam
Warwick Manufacturing Group, The University of Warwick, Coventry CV4 7AL, UK
e-mail: P.Srirangam@warwick.ac.uk
© Springer Nature Switzerland AG 2021
J. P. Davim (ed.), Welding Technology, Materials Forming, Machining
and Tribology, https://doi.org/10.1007/978-3-030-63986-0_5
167