Abstract
Summary The hybrid joining method has been proposed as a joining method which can be applied to the high precision assembly of thin sheet products. It has been confirmed that good joining results with 2–6 mm thick steel can be obtained consistently using this joining method. In this report, the plug joint and the hybrid joint welding of 1–6 mm thick aluminium alloy sheet were investigated. In plug welding, good results could be obtained only with a limited range of welding conditions using He-AC-TIG. Moreover, to get these results continuously was very difficult. However, by using a hybrid joint with a projection whose height was about 1/3 of the sheet thickness, consistent joining results could easily be achieved in short arc time. In the tensile test of hybrid welded joints, fracture occurred at the joint interface because of shearing forces and joint strength showed constant values.
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