Flexible drill and method of joining nitinol to dissimilar metals

A method of joining nitinol to a dissimilar metal, comprising the steps of

• providing a tubular nitinol member consisting essentially of a nitinol wire with a nitinol core and covered by a coating for surface bearing in the proximity of a tubular member of a dissimilar metal, a diameter of the tubular nitinol member being smaller than a diameter of the tubular member of the dissimilar metal, wherein the nitinol wire forms a flexible part of a shaft of a surgical drill, and the tubular member is a stainless steel shaft forming a rigid part of the shaft of the surgical drill;
• forming a plurality of cross-holes through the tubular member by drilling across a diameter of the tubular member from a top surface to a bottom surface, the plurality of cross-holes extending in a direction perpendicular to a longitudinal axis of the tubular member;
• inserting the nitinol member within the tubular member so that the cross-holes interface a top surface of the nitinol member;
• and
• joining the nitinol member directly to the tubular member of the dissimilar metal by conducting fusion welding by creating welding plugs in the cross-holes using laser while keeping the welding away from joint regions therefore allowing heat to be kept away from high stress regions which are subjected to most torque during flexing or bending of the shaft, wherein joining the nitinol member directly to the tubular member of the dissimilar metal is conducted with no intermediate piece or material disposed between the nitinol member and the tubular member.