A safe and reliable method of bonding dissimilar metals or materials in either a laboratory or factory environment.

The Need

Fusion welding is a traditional technique utilized to bond metals together, but provides unreliable welds which are prone to failure upon bonding dissimilar metals or materials together. Thus, interlocking mechanisms such as clinch-locks are introduced to overcome the limitations of fusion welding. This requires thicker materials to be joined together to create a reliable seam. A welding technique that bonds two dissimilar materials together while maintaining structural integrity and load capacity would help reduce production costs for a variety of different industries.

The Market

A variety of manufacturing companies involved in canning, automotive, battery, micro-mechanical devices and biomedical industries would benefit from improved welding for smaller scale applications.

  • The global market for welding applications in the automotive/transport industry is expected to reach $5.1 billion in 2014 (BCC Research)
  • The global market for welding product applications in the electronics and medical sector is expected to reach $751 million in 2014 (BCC Research)
  • The global market for welding machinery is forecast to reach US $12.8 billion by the year 2015 (Global Welding Machinery Market, Global Industry Analysts, Inc., 2010)

The Technology

Researchers at The Ohio State University, led by Dr. Glenn Daehn, developed a method of factory-safe explosive welding. Laser-driven collision spot welding provides a more efficient method to join dissimilar materials together. By utilizing high-intensity laser pulses, structural integrity of the metallurgical bond will be maintained while minimizing the change in base metal temperature due to heat.

  • High speed: demonstrated 600 welds/minute, which can be located to form spots or seams, etc.
  • Energy efficient: less energy/weld than fusion or ultrasonic welding
  • Any combination of metals and/or dissimilar materials such as composites, nano-structured materials, metallic glasses can be joined together
  • Metallic structures can be joined in a bond region of size scale from millimeters to microns

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