Joining the dissimilar metal pair of NiTi to stainless steel is of great interest for implantable medical applications. Formation of brittle intermetallic phases requires that the joining processes used for this dissimilar pair limits the amount of over-melting and mixing along the interface. Thus, because of its ability to precisely control heat input, laser joining is a preferred method. This study explores a method of using a cup and cone interfacial geometry, with no filler material, to increase the tensile strength of the joint. Not only does the cup and cone geometry increase the surface area of the interface, but it also introduces a shear stress component, which is shown to be beneficial to tensile strength of the wire as well. The fracture strength for various cone apex angles and laser powers is determined. Compositional profiles of the interfaces are analyzed. A numerical model is used for explanation of the processing parameters.

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