Abstract
This novel research aims to examine the macro and microstructural bonding region development during magnetic pulse welding (MPW) of dissimilar additive manufactured (AM) laser powder-bed fusion (L-PBF) AlSi10Mg rod and AA6060-T6 wrought tube, using both optimal- and high-energy welding conditions. For that purpose, various joint characterisation methods were applied. It is demonstrated that high-quality hermetic welds are achievable with adjusted MPW process parameters. The macroscale analysis has shown that the joint interfaces are deformed to a waveform shape; the interface is starting relatively planar, with waves forming and growing in the welding direction. The observed thickening of the flyer’s wall after welding is the result of its diametral inward deformation, taking place during the process. A slight increase in microhardness was adjacent to the faying interfaces; a higher increase was measured on the AlSi10Mg material side, while a smaller one was observed on the AA6060 side. Along the wavy interfaces, resolidified “pockets” of material or occasionally discontinuous short layers exhibiting different morphologies, were detected. The jet residues are typically located towards the end of the weld, confirming a temperature rise that exceeds the melting temperature of both alloys. Far from the weld zone, extremely thin-film deposits were clearly observed on the inner flyer surfaces. The formation of isolated Si particles and thin-film deposits may point out that the local increase in temperatures leads to melting or even evaporation vaporisation of superficial layers from the colliding parts. It is worth noting that this type of jet residue was discovered for the first time in the present research. The current research work is expected to provide an understanding of weld formation mechanisms of additively manufactured parts to conventional wrought parts conforming to existing wrought/wrought weld knowledge.
Highlights
Joining by welding plays an important role in the fabrication of mechanical assemblies created from parts with different properties
Gas gun welding, laser impact welding, vaporising foil actuator welding, and magnetic pulse welding (MPW) are the five main joining techniques based on impact phenomena proven to date
Tests MP-welded samples were subjected to fine leak testing to determine the hermeticity of the joints
Summary
Joining by welding plays an important role in the fabrication of mechanical assemblies created from parts with different properties. The L-PBF technique has been broadly investigated and is currently the most used technique in AM of Al-alloys, in terms of high-quality near full-density parts This technology enables the fabrication of complex aluminium components exhibiting unique microstructures that are hard to create by conventional methods. Very high solidification rates (of 0.1 × 103 –5 × 103 mm·s−1 ) and high cooling rates (typically 5 × 105 K·s−1 and higher) accompanying the L-PBF processing of AlSi10Mg components result in the formation of extremely fine microstructures and lead to improved quasi-static mechanical properties that can even outperform those of parts manufactured by conventional fabrication processes Awd and his colleagues [28] examined fatigue cracking of AM L-PBF-AlSi10Mg by X-ray computed tomography and studied the influence of microstructural homogeneity on fatigue strength. The novelty of the present work focused mainly on the characterisation of both optimal- and high-energy welding conditions to check weldability under different MP welding conditions
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