A Semi-Analytical Model for the Heat Generation during Hybrid Metal Extrusion and Bonding (HYB)

Abstract

Hybrid Metal Extrusion and Bonding (HYB) is a novel solid-state welding method for metals and alloys that utilises continuous extrusion as a technique to enable aluminium filler metal additions. In the present study, a new semi-analytical model for the heat generation during aluminium butt welding is presented. As a starting point, the classical Rosenthal thin plate solution for the pseudo-steady-state temperature distribution around a fully penetrating line source is invoked. Then, the associated heat generation is calculated by considering the individual contributions from the tip of the rotating pin, the pin shoulder, and the filler metal additions on the net power input. In a calibrated form, the model yields thermal efficiency factors that are in close agreement with those obtained from more sophisticated finite element analyses but with considerably less computational effort.

Rapid Calculation of Residual Stresses in Dissimilar S355–AA6082 Butt Welds

“…As a starting point, the welding conditions such as welding speed, rotational speed, and geometry of the tool were fixed. These input parameters were used to calculate the corresponding heat input by using a semi-analytical heat generation model already proposed by Leoni et al [24]. The obtained heat input was then used both in FE and analytical model to calculate the thermal and residual stresses.…”

“…It is worth noting that p 0 , the actual thermal power of the pin, is calculated employing the model described by Leoni et al [24] and summarized with the following equation:…”

“…Recently, a new solid-state joining method known as the hybrid metal extrusion and bonding (HYB) process has appeared on the horizon [22]. So far, various experimental studies of the HYB process applied to similar and dissimilar metals welds were carried out in order to better understand and predict the effect of process parameters on welded materials; however, only recently was a great effort spent in the development of numerical models [23,24]. Recently, good experimental results were found for dissimilar aluminumsteel butt welds obtained by the HYB technique [25][26][27].…”

Effect of tool size on AA6061‐T6 double‐sided friction stir welds

“…However, their welding by conventional fusion welding processes is not sometimes suitable due to crack formation during solidification, porosity, high residual stresses, large welding deformation, and formation or growth of unwanted brittle intermetallic compounds 2,3 . For aluminum and its alloys, the solid‐state joining methods offer considerable advantages over other fusion joining processes 4,5 . For example, ultrasonic welding has been implemented as a promising spot‐welding process for aluminum alloys 6 .…”

“…Explosive welding has also been adopted for the joining of similar or dissimilar metals such as steel 7 or aluminum–stainless steel welds 8 . A hybrid metal extrusion and bonding welding method has been studied by researchers that utilizes the principle of continuous extrusion as a technique to enable addition of filler wire material during welding 4,5 . Another solid‐state joining method friction stir diffusion welding has been studied using a specially designed tool that results in diffusion bonding between overlap sheets/plates 9 .…”