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Multi-Material Joining

Friction Element Welding (FEW)

Friction Element Welding is a multi-material joining process. It utilizes a consumable fastener, named as friction element, to secure two sheets of metal. The process forms spot joints of different material combinations such as Aluminum-Steel, Magnesium-Steel, and Composite Polymer-Steel. 

It is carried out in 4 steps:

  1. Penetration

  2. Cleaning

  3. Welding

  4. Compression.

The process has several advantages over other multilateral joining processes.

Chipping in FEW

Chipping_4kN4000RPM.jpg

My research is focused on a newly discovered limitation of the process. Thin strands of aluminum are formed during the penetration step, termed as chipping.

 

These thin segments accelerate the corrosion of the joint, thus affecting its longevity. Several methods are researched in the automotive industry to overcome the drawbacks associated with this limitation. 

I am part of a research team tasked with developing prototype technology to reduce process time and energy consumption. My role in the team comprises designing modifications to the existing equipment and testing the new setups for industrial viability through analysis of process metrics: time, energy, and strength.

Methods of Chipping Mitigation

© Amit Bajirao Deshpande 2021
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