joining Al to Al

[knowlittle]

I need to fabricate a part from aluminum. Basically, it has a thin disk (33 mm x 0.6 mm) connected to a pin (4 mm x 9 mm). I know I can machine it from a round rod with much patience. But I would like to explore the possibility of joining the disk and pin after fabricating them separately.

The disk will be polished on the flush side (diamone paste). The assembly will be electroless nickel plated fist, and then hard chrome plated on the flush side.

 

[KENAT]

Press fit, brazing, welding would be the processes that jump to mind.

The disk is pretty thin, what's the loading on it?

Plating 'inseperable assemblies' can be problematic, I'm not sure how nickel is but I know the cracks/changes in material properties can affect other methods.

Posting guidelines faq731-376

http://eng-tips.com/market.cfm?

(probably not aimed specifically at you)
What is Engineering anyway: faq1088-1484​

 

[mfgenggear]

it's my opinion
it's cheaper and easier to turn from bar.

the handling will be the issue with assy.

however that said, tig/mig tack weld & low temp vacuum braze.

 

[knowlittle]

1) Loading on the part: Highest loading will come from polishing the disk. No loading from operation. It is a collection plate of outgassing stuff from plastics. The pin is just to hold the disk from falling off.

2) The flush side cannot have a crevice.