Abstract
Hybrid Metal Extrusion & Bonding is a new solid state joining technique developed for aluminium alloys. By the use of filler material addition and plastic deformation sound joints can be produced at operational temperatures below 400 °C. This makes the HYB process more flexible and less vulnerable to defects compared to conventional solid state processes. Here, we present the results form an exploratory investigation of the mechanical integrity of a 4 mm AA6082-T6 HYB joint, covering both hardness, tensile and Charpy V-notch testing of different weld zones. The joint is found to be free from internal defects like pores, cavities and kissing bonds. Still, a soft heat affected zone (HAZ) is present. The joint yield strength is 54 % of the base material, while the corresponding joint efficiency is 66%. Therefore, there is a potential for further optimization of the HYB process. This work is now in progress.
Highlights
The unique physical and mechanical properties of aluminium alloys, as the Al-Mg-Si alloys, makes them attractive for a wide range of structural applications and welded assemblies [1]
The joint is found to be free from internal defects like pores, cavities and kissing bonds
In order to evaluate the mechanical performance of the Hybrid Metal Extrusion & Bonding (HYB) joint, the properties achieved must be compared with corresponding results reported for conventional welding techniques as gas metal arc (GMA) welding and friction stir (FS) welding
Summary
The unique physical and mechanical properties of aluminium alloys, as the Al-Mg-Si alloys, makes them attractive for a wide range of structural applications and welded assemblies [1]. Within the automotive industry welding is often required as part of the fabrication process. Even though the Al-Mg-Si alloys are readily weldable, a variety of weld defects may occur. The excessive heat generation associated with the traditional welding processes makes them vulnerable to heat affected zone (HAZ) softening due to the reversion of the hardening precipitates which form during artificial ageing [3]. Solid state joining offers several advantages compared to traditional fusion welding when it comes to structural and mechanical integrity of the weldments
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