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To join two aluminum parts, you could, in theory, place one atop the other and wait 100 years. The two will eventually form a solid-state bond. Metals naturally want to join with each other.
Lightweighting is one of the biggest challenges facing manufacturers today in the automotive, aerospace, maritime and rail industries. The push for new materials is forcing engineers in these industries to explore cost-effective alternatives and develop new assembly processes.
As manufacturers expand the use of aluminum, titanium, magnesium and other high-strength, lightweight alloys, interest in alternative joining technologies is increasing.
Ultrasonic welding can handle most plastics assembly applications. Other friction-based processes, such as vibration welding and spin welding, can usually tackle the rest. However, that necessitates investing in three separate machines at considerable cost.
SOUTH BEND, IN—It’s 20 feet tall, weighs about 400,000 pounds and is now making its way from South Bend to Connecticut: It's the world's largest friction welding machine. Pratt & Whitney will use the machine, made by Manufacturing Technology Inc., to weld large-diameter jet engine components.
Established methods—like ultrasonic and resistance welding—increasingly face competition from advancing technologies like laser, friction and micro welding.
