Abstract
This paper presents the results of a series of tests involving the production of permanent joints between two metallic components. This was achieved by forging discs of aluminium onto shafts of copper, mild steel, alloy steel and titanium onto which grooves of various geometries had been machined. The groove geometries used included, square and triangular sectioned grooves, a helical screw thread and a knurled surface used in conjunction with the square and triangular shaped grooves. The influence of groove geometry on the degree of metal flow, or “fill-out” into the grooves and the resulting joint strength under both axial and torsional loading was assessed for a range of applied forging loads. The relationship between the relative hardness of the disc and shaft material on the integrity of the joints formed was also investigated. The results obtained indicated that this plastic flow technique can be used to produce high strength permanent joints using relatively unsophisticated tooling. In addition the process lends itself to automation and could provide an inexpensive method of producing sound permanent joints.
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