Integrated Computational Materials Engineering for Welding (ICME) develops new process for dissimilar metal joining

Members of Ohio State's welding engineering program developed a new process for cost-effectively joining dissimilar metals such as aluminum to steel, magnesium to steel, and titanium to nickel. The team is consisted of Prof. Wei Zhang, Prof. Menachem Kimchi, Ms. Ying Lu (Ph.D. candidate), and Mr. Ellis Mayton (undergraduate research assistant).

The new technique uses ultrasonic plus resistance spot welding (U+RSW) to create high-strength joints between two sheet metals. While automobile manufacturers are using more bi-metallic structures such as those made of aluminum and steel, a cost-effective way to join them had not yet been developed.

A feasibility study showed promising results and a provisional patent was filed. Practical application of this technique extends beyond automotive industry to aerospace, healthcare and any other industry needing a quick, cost-effective method to join dissimilar metals.

A one-page summary of the new process can be downloaded here.  More detailed results are available in their 2019 paper in Materials & Design.