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Joining dissimilar metals using cold metal transfer process: a review

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Abstract

In modern engineering applications, there is a growing demand for reducing the overall component weight without compromising strength and integrity. This has led to the combined use of multiple materials. Conventionally, various methodologies such as mechanical fastening, friction stir welding, and transition joints have been proposed to join dissimilar metals. It is worth noting that components made of dissimilar metals present several challenges when it comes to metallurgical joining. These challenges arise from the chemical and thermal properties of the metals, which result in the formation of intermetallic compounds at the interfaces and the occurrence of thermal stresses in the joints. Cold metal transfer method employs controlled short circuiting to minimize heat input, making it ideal for dissimilar metal welding. This reduced heat input effectively prevents excessive thermal stress, distortion, and the formation of brittle intermetallic compounds at the joint interfaces. The current work is presented with a view of providing the various process parameters adopted across combinations of dissimilar metals using CMT method, the complications in the fabrication of joints, and the respective counter actions carried out to attain a solid metallurgical bonding between the metals.

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Acknowledgements

The authors are thankful to Dr. Nagahanumaiah, Director, Central Manufacturing Technology Institute, Tumkur Road, Bangalore, India, for extending support and encouragement throughout the course of this work.

Funding

This work was supported by Department of Science and Technology, India, under Grant DST/TDT/AMT/2017/145(G).

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Authors and Affiliations

  1. Central Manufacturing Technology Institute, Bengaluru, 560022, India

    B. N. Manjunath & H. S. Karthik

  2. Karunya Institute of Technology and Sciences, Coimbatore, 641114, India

    P. Jayaprakash & D. Arulkirubakaran

  3. Department of Mechanical Engineering, Indian Institute of Technology Tirupati, Tirupati, 517506, India

    Avinash Mishra, D. V. Kiran & N. Venkaiah

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  1. B. N. Manjunath
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Correspondence to B. N. Manjunath.

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Manjunath, B.N., Jayaprakash, P., Mishra, A. et al. Joining dissimilar metals using cold metal transfer process: a review. Weld World 68, 579–591 (2024). https://doi.org/10.1007/s40194-023-01639-8

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