An Innovative Approach for Manufacturing of Thin Welded Blanks and Coils

Abstract

Abstract This study presents a novel approach for fabricating thin welded plates with excellent surface finish and physical properties using friction stir welding process. Similar and dissimilar materials were welded under various conditions, followed by cold-rolling operations to the desired thicknesses. For welding of similar material, an ultimate thickness of 70 µm was achieved from 1 mm raw aluminum alloy-1100. In the next stage, where aluminum and copper sheets with the thickness of 0.5 mm were welded together, bi-material foils with final thickness of 200 µm were fabricated. Results indicate that the presented approach can be replaced with costly fusion processes especially for ultra-thin joints. Keywords: ColdDissimilarFrictionJointRollingSimilarStirThinWelding