High Speed Pulse Welding of Powder Metalurgy Automotive Components

High speed pulse welding creates a solid state weld between Powder Metallurgy materials (P/M) and to wrought materials. The fast weld pulse process is compatible with and advantageous to P/M component welding. This paper describes seven P/M alloys welded to 1010 sheet metal coupons. The carbon content and density are increased in seven of the alloys creating 37 welded material combinations. Carbon levels to 0.8 % were welded with densities of 6.6, 6.8, and 7.0 gram per cc. Each P/M group was evaluated by optimizing the weld schedule, then making specimen for strength determinations. Increasing density, carbon and alloy improved assembly strength.