Advanced Welding of Dissimilar Materials for Aerospace and Automotive Applications

The aerospace and automotive sectors are now experiencing a growing need for lightweight and high-performance components. As a result, there is a significant interest in investigating new welding methods that can effectively fuse different materials. The process of welding different materials poses notable difficulties as a result of disparities in physical qualities, metallurgical attributes, and thermal expansion coefficients. The research starts by examining the rationales for employing diverse materials in various sectors, emphasising the benefits they provide in relation to decreased weight, greater fuel economy, and improved mechanical characteristics. Following this, the study explores a range of sophisticated welding techniques that have arisen in response to these issues. This paper examines several fusion welding techniques, including laser welding, electron beam welding, and friction stir welding. Each approach is discussed in detail, with a comprehensive description of its fundamental concepts. This discussion focuses on the advantages of each approach in relation to the reduction of heat-affected zones, the attainment of precise control over the welding process, and the minimization of intermetallic compound formation. The study also emphasises the use of case studies and practical instances to showcase the effective implementation of sophisticated welding techniques on dissimilar materials. The feasibility and efficiency of these approaches in combining incompatible materials, such as aluminium to steel, titanium to composites, and others, are exemplified by instances observed in the aerospace and automotive sectors