Table 2 Combinations of DMW of non-ferrous metals

Aluminum to titanium

This combination has not been accomplished successfully by conventional arc welding processes.

These metals form intermetallic compounds during fusion that are exceedingly brittle (Ti₃Al, TiAl, and TiAl₃).

Korenyuk (1975)

Titanium to nickel

An attempt to weld Ti and Ni using TIG was not successful. However, the use of columbium or copper alloy as an insert led to a joint without harmful intermetallic compounds.

These metals form brittle intermetallic compounds with almost every element contained in the alloys (Ni, Fe, Cr, Mn, and Si).

Gorin (1964), Lv et al. (2012)

Titanium to copper

The joints with the highest tensile strength and ductility were those produced with Ti-30Cb and Ti-3Al-6.5Mo-11Cr

The physical properties of titanium differ greatly from those of copper.

Mikhailov et al. (1965)

The solubility of copper in α-titanium is low.

Copper to aluminum

Before GMAW welding, a layer of a silver-based filler metal (Ag-15.5Cu-17.5Zn-18Cd) was deposited on the surfaces of the copper work piece.

The use of this combination is limited by the formation of brittle intermetallic compounds during the fusion process.

Lezovskaya and Rabkin (1966), Cook and Stavish (1956)

The chemical compound CuAl₂ contains 54.1% copper and will form a eutectic reaction with a solid solution of copper in aluminum.

Copper alloys to nickel

Copper and nickel are mutually soluble in each other.

Welding these two metals and their alloys does not present serious problems.

O'Brien (2011)

Copper-nickel or nickel-copper filler can be used.

Magnesium to aluminum

Due to the brittleness of the intermetallic compound, the intermetallic formation has to be controlled and kept as low as possible.

The intermetallic compound is found in the phase diagram between Mg and Al: Al₂Mg₂, Al₁₂Mg₁₇, and Al₃₀Mg₂₃, even at relatively low temperatures.

Murray (1982)

There is a small difference in the melting point between magnesium and aluminum.