Abstract
The hybrid metal extrusion and bonding (HYB) process is a new solid-state joining technique developed for aluminum alloys. By the use of filler material addition and plastic deformation sound joints can be produced at operating temperatures below 400 °C. The HYB process has the potential to compete with commonplace welding technologies, but its comparative advantages have not yet been fully explored. Here, we present for the first time the results from an exploratory investigation of the mechanical integrity of a 4-mm AA6082-T6 HYB joint, covering both hardness, tensile and Charpy V-notch testing. The joint is found to be free from defects like pores, internal cavities and kissing bonds, yet a soft heat-affected zone (HAZ) is still present. The joint yield strength is 54% of that of the base material, while the corresponding joint efficiency is 66%. The indications are that the HYB process may compete or even outperform conventional welding techniques for aluminum in the future after it has been fully developed and optimized.
Highlights
Aluminum alloys, as the Al–Mg–Si alloys, exhibit unique physical and mechanical properties making them attractive for a wide range of structural applications and welded assemblies [1, 2]
The total width of the heat-affected zone (HAZ) is seen to be 25 mm, whereas the observed asymmetry in the hardness profile and FM and BM flow patterns is probably a reflection of the pertinent difference in the force acting on the advancing side (AS) and retreating side (RS), respectively during pin rotation
The hardness measurements along the vertical mid-section revealed that the hardness was highest in the top region, where it reached a value of 93 HV
Summary
As the Al–Mg–Si alloys, exhibit unique physical and mechanical properties making them attractive for a wide range of structural applications and welded assemblies [1, 2]. The Al–Mg–Si alloys are readily weldable, the excessive heat generation associated with the traditional welding processes makes them vulnerable to HAZ softening due to reversion of the hardening precipitates which form during artificial aging [3]. Strict base plate and profile tolerances are required, as lack of filler material addition may result in insufficient material feeding and to undercuts and internal defects in the joint [6, 12]. These limitations need to be overcome in the future
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