Award-Winning Metal Process Redefines Manufacturing Limits

As the demand for lightweight materials in aerospace and electric vehicle industries continues to rise, aluminum alloys have become increasingly popular due to their versatility and strength-to-weight ratio. However, welding aluminum alloys often presents challenges, including defects and reduced material strength caused by excessive heat input. To address these issues, the Metal Industries Research & Development Centre (MIRDC), with support from the Department of Industrial Technology (DOIT), Ministry of Economic Affairs, has developed the groundbreaking 4D (3D+Dissimilar) Printed Solid State Process. This innovation has earned global recognition, winning an R&D 100 Award in 2022 and a Bronze Medal at the Edison Awards in 2023.

Unlike traditional welding, which requires extremely high temperatures to melt metals, the 4D Printed Solid State Process uses a high-speed rotating stirring tool to generate frictional heat. This approach significantly lowers the required welding temperature, consuming less energy while preserving the structural integrity of the materials. For example, while aluminum alloy typically melts at 660°C, this process achieves strong and high-quality bonds at a much lower temperature range of 400°C to 500°C, minimizing thermal damage and enhancing material strength.

The process is particularly well-suited to meet the increasing demand for products made from dissimilar metals, a growing trend in complex product designs. MIRDC has built a demonstration production line and trial platform, advancing from fundamental stirring tool material research to the design of optimized tool geometries. Collaborating with international organizations, MIRDC has developed specialized stirring tool materials and employs Computer-Aided Engineering (CAE) to predict welding quality, refine parameters, and visualize processes digitally.

In partnership with domestic machine tool manufacturers, MIRDC integrates intelligent real-time monitoring and control into the system. This holistic approach provides the industry with a comprehensive solution encompassing process development, material innovation, equipment manufacturing, and quality verification, delivering unparalleled welding technology to both domestic and international markets.