Cold welding

Cold welding or contact welding is a solid-state welding process in which joining takes place without fusion/heating at the interface of the two parts to be welded. Unlike in the fusion-welding processes, no liquid or molten phase is present in the joint.

Cold welding was first recognized as a general materials phenomenon in the 1940s. It was then discovered that two clean, flat surfaces of similar metal would strongly adhere if brought into contact under vacuum. Newly discovered micro- and nano-scale cold welding has already shown great potential in the latest nanofabrication processes.

The reason for this unexpected behavior is that when the atoms in contact are all of the same kind, there is no way for the atoms to “know” that they are in different pieces of copper. When there are other atoms, in the oxides and greases and more complicated thin surface layers of contaminants in between, the atoms “know” when they are not on the same part.

Applications include wire stock and electrical connections (such as insulation-displacement connectors).

Mechanical problems in early satellites were sometimes attributed to cold welding.

In 2009 the European Space Agency published a peer reviewed paper detailing why cold welding is a significant issue that spacecraft designers need to carefully consider. The paper also cites a documented example from 1991 with the Galileo spacecraft high-gain antenna.

One source of difficulty is that cold welding does not exclude relative motion between the surfaces that are to be joined. This allows the broadly defined notions of galling, fretting, sticking, stiction and adhesion to overlap in some instances. For example, it is possible for a joint to be the result of both cold (or "vacuum") welding and galling (and/or fretting and/or impact). Galling and cold welding, therefore, are not mutually exclusive.

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