Interface Formation during Collision Welding of Aluminum

Benedikt Niessen,Stefan Böhm,Christoph Leyens,Christoph Leyens,Eckhard Beyer,Jörg Bellmann,Jörg Bellmann,Peter Groche,A Erman Tekkaya,Eugen Schumacher,Jörn Lueg-Althoff,Martin Franz-Xaver Wagner,Marcus Böhme

doi:10.3390/met10091202

Abstract

Collision welding is a high-speed joining technology based on the plastic deformation of at least one of the joining partners. During the process, several phenomena like the formation of a so-called jet and a cloud of particles occur and enable bond formation. However, the interaction of these phenomena and how they are influenced by the amount of kinetic energy is still unclear. In this paper, the results of three series of experiments with two different setups to determine the influence of the process parameters on the fundamental phenomena and relevant mechanisms of bond formation are presented. The welding processes are monitored by different methods, like high-speed imaging, photonic Doppler velocimetry and light emission measurements. The weld interfaces are analyzed by ultrasonic investigations, metallographic analyses by optical and scanning electron microscopy, and characterized by tensile shear tests. The results provide detailed information on the influence of the different process parameters on the classical welding window and allow a prediction of the different bond mechanisms. They show that during a single magnetic pulse welding process aluminum both fusion-like and solid-state welding can occur. Furthermore, the findings allow predicting the formation of the weld interface with respect to location and shape as well as its mechanical strength.

Highlights

One of the biggest challenges today is climate change and its impact on the environment and human society
Results with a Ultra Plus scanning electron microscope (SEM), using the secondary electron detector to validate the results of the ultrasonic examination and to determine how the
The upper boundary collision angle increased both with higher flyer thickness and increased impact velocity

Summary

Introduction

One of the biggest challenges today is climate change and its impact on the environment and human society. Driven by politics and self-motivation, the industry is increasingly striving for sustainable. Metals 2020, 10, x FOR PEER REVIEW sustainable Metals. 2020, 10,products and manufacturing processes, e.g., by introducing clean production methods without toxic components and with less energy and raw material consumption. New products have to be more environmentally friendly. The consistent lightweight design products and manufacturing processes,factor e.g., by introducing clean Reliable production methods without in the transport sector is an important to reduce emissions. Joining techniques aretoxic key components and with less energy and raw material consumption. Conventional be more environmentally friendly.For example, consistent lightweight design in the transport fusion-based joining processes, reachthetheir technological limits when it comes to sector is an important factor to reduce emissions

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Results

Discussion

Conclusion