Conformal Interference Joining
Conformal interference joints are mechanical interlocks between two components, which can be composed of similar or dissimilar materials. Electromagnetic forming and vaporizing actuators can accelerate closed shapes inward or outward with velocities greater than 100 m/s. Upon impact under these conditions, one material will conform closely to the other and a state of residual stress will remain, holding the two components together. Joint strength exceeds the strength of the weaker of the two materials in a properly designed joint. Thus, this method represents a complementary method to welding. Unlike welding, however, there are no heat-affected zones and arbitrary dissimilar materials can be joined. This method is practiced commercially; we are working to extend the methods and the design science.