Abstract
The impact extrusion of axially arranged steel-aluminium billets was studied in this research. Two different bi-material billet concepts were considered: discrete and prejoined billets. Discrete billets were formed in order to achieve a joint through plastic deformation. Prejoined billets were created by friction welding beforehand and their behaviour under plastic deformation was investigated. Pressure superposition was utilised to improve the resulting bond strength by changing the stress state in the joining zone during forming. Depending on the magnitude of the applied counter pressure, the resulting bond strength could be influenced positively. It was also shown that the effect of die shoulder angle was not significant for the achieved bond strengths. The findings suggest that elevated billet temperatures can eliminate the need for counter pressure.
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