Cold Pressure Welding: Tips for Success

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Discussion Overview

The discussion revolves around the challenges and methods of cold pressure welding, particularly focusing on joining two sheets of metal through lap joints. Participants explore various techniques, equipment, and applications related to cold welding, including practical experiences and theoretical insights.

Discussion Character

  • Exploratory
  • Technical explanation
  • Debate/contested

Main Points Raised

  • A participant, a mechanical engineering student, shares their unsuccessful attempts at cold welding using simple methods like hammering and pressing with a vise, seeking advice on potential mistakes.
  • Another participant questions the effectiveness of the methods used, suggesting that cold welding requires specific conditions that may not be met by the techniques mentioned.
  • A seller of cold pressure welding equipment notes that their equipment is not suitable for sheet metal due to the high pressure required, but mentions its effectiveness on wires and rods, including welding aluminum to copper.
  • One participant recalls seeing cold welding of aluminum sheets in aerospace applications, describing a method involving a rotating head that applies pressure while moving along the sheets.
  • Another participant expresses surprise at the lack of information available online regarding cold welding of sheet metal, noting that many sources claim it is not feasible.
  • A repeated comment mentions a method seen on a show, indicating that explosives were the only successful means of cold welding two sheets of metal.

Areas of Agreement / Disagreement

Participants express differing views on the feasibility and methods of cold welding sheet metal, with no consensus reached on the effectiveness of the techniques discussed or the conditions necessary for successful welding.

Contextual Notes

Some participants reference specific applications and methods that may not be universally applicable, highlighting the dependence on material types and welding conditions. There are unresolved questions regarding the technical requirements for successful cold welding of sheet metals.

z_ahutd
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Hi guys. As a mechanical engineering final year student, I was assigned to design and build a cold welding prototype to weld just two sheets of metal together by lap joint. Before I actually start the designing process, I tried to cold weld the two sheet metals together by using simple methods ie, knocking a punch with a hammer to the metals, pressing using a bench vise etc. None of it would join the two together. I used different kinds of materials and thickness (Copper & Aluminium sheet with 0.5mm, 0.8mm and 1.0mm) but all failed. I don't know what is my mistake here. Can anyone help? Thanks in advance.
 
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So what method of jointing are you going to use? Riveting? Seam rolling? Crimping? Adhesives? Or are you actually expecting that a hammer/punch or vice creates the conditions that cold pressure welding will occur under?

You do know that two pieces of metal won't just stick together by themselves right?
 
Hi guys,
just found this thread by accident. I sell cold pressure welding equipment but it can't be used for sheet metal. The pressure you would need for that type of material is enormous. Take a look at some head on car smashes and you might just see that some of the metal frame welds together. Our equipment works on wires, rods and square or flat metal bars. We can even weld aluminum to copper. You can see our equipment here: http://www.coldpressurewelding.com/cms/index.php Hope this info is useful for you. br Alan
 
I have seen this being done with aluminum sheet for aerospace applications. If I remember correctly, they were using a rotating head that pressed down onto the two sheets over an anvil. The sheets were drawn through the device to move the pressure point along the desired bead. It was stated in the video I saw, that in applications requiring greater strength, rivets were used instead.
 
Surprised I can't find anything about this on the web, and those that offer cold welding claim it's not possible for sheet metal... Very odd.
 
TheFlynn said:
I have seen this being done with aluminum sheet for aerospace applications. If I remember correctly, they were using a rotating head that pressed down onto the two sheets over an anvil. The sheets were drawn through the device to move the pressure point along the desired bead. It was stated in the video I saw, that in applications requiring greater strength, rivets were used instead.

It's called "http://www.google.com/search?q=friction+stir+welding"".
 
Last edited by a moderator:
I saw this on Mythbusters. The only way they could cold weld two sheets of metal were with explosives.
 

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