Dissimilar Impact Welding of 6111-T4, 5052-H32 Aluminum Alloys to 22MnB5, DP980 Steels and the Structure–Property Relationship of a Strongly Bonded Interface

Liu, Bert; Vivek, Anupam; Presley, Michael; Daehn, Glenn S.

doi:10.1007/s11661-017-4429-7

Cited by 21 publications

(11 citation statements)

References 22 publications

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“…The SAED ring pattern was well indexed to the AlFe 3 with a space group of Fm3m, which is thermodynamically stable [34,35]. Liu et al [22,27] also observed complex intermetallic AlFe phases at the interface zone such as AlFe, AlFe 3 , Al 5 Fe 2 , and Al 3 Fe. Perhaps, meta-stable intermetallics such as Al 2 Fe with low symmetry would be transformed to a high-symmetry phase [36].…”

Section: Microstructure Investigation In the Welding Interfacementioning

confidence: 82%

“…The vaporizing foil actuator welding (VFAW) is the one of the explosion welding, which does not involve the conventional full melting of the materials being joined. It applies substantially high pressure to the bottom of a flyer sheet as depicted in Figure 1a to make it collide with a target sheet, which tends to induce metallic bonding [22][23][24] at the interface for permanent welding. When a high current is instantly applied to the aluminum foil, it is vaporized from solid to gas, directly, which tends to generate tremendously high pressure as shown in Figure 1b.…”

Section: Introductionmentioning

confidence: 99%

“…Vivek et al [29,30] successfully carried out the welding between the titanium-copper alloy and the BMG (Bulk Metallic Glass)-Cu110 alloy in which they observed the morphology of welded interface with respect to the impact velocity of the flyer sheet. Liu et al [22] have investigated Al x Fe y phases at the welded interface with supported by EDS-SEM, EBSD, and TEM analyses. It has also been researched to optimize the process parameters such as impact angle, standoff distance, and input energies, etc.…”

Section: Introductionmentioning

confidence: 99%

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Dissimilar Materials Welding with a Standoff-Free Vaporizing Foil Actuator between TRIP 1180 Steel Sheets and AA5052 Alloy

et al. 2021

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This paper mainly demonstrates an advanced type of the vaporizing foil actuator welding (VFAW) process between GPa-grade steel (TRIP1180) and aluminum alloy (AA5052-H32) without applying standoff. To secure a flying distance during the VFAW process, the preformed target sheet shaped like a circular indentation has been utilized. It is necessary to optimize process parameters integrated with geometrical design of the preform since the welding strength can be decreased beyond the optimum input energy in the standoff-free VFAW process. The welded surface was evaluated by SEM-EDS, XRD, EBDS, and TEM to analyze the welding mechanism and composition at the welding interface. The diffusion zone including the AlFe3 phase was observed at the welded interface which has high grain density due to the high-speed impact by increasing the welding strength, which leads to the perfect welding between the dissimilar materials.

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Section: Microstructure Investigation In the Welding Interfacementioning

confidence: 82%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Dissimilar Materials Welding with a Standoff-Free Vaporizing Foil Actuator between TRIP 1180 Steel Sheets and AA5052 Alloy

et al. 2021

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“…Since VFAW generates highly deformed grains with high dislocation densities and recrystallized grains of sizes less than 1 μm on the Al side at the weld interface [41], running the simulation with lattice diffusion coefficients does not represent the microstructure outcome of annealed VFAW welds very well. This conclusion was reached after attempting to run the simulation using the lattice diffusion coefficients and observing large discrepancies between the calculated and experimental results as explained in detail in section 3.3.…”

Section: 𝐽 = −𝐷 ̃𝜕𝑐mentioning

confidence: 99%

Microstructure and Fracture Toughness of an Aluminum-Steel Impact Weld and Effect of Thermal Exposure

Kohlhorst

Kapil

Chen

et al. 2021

Metall Mater Trans A

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Welding of aluminum alloys to steel is increasingly important in manufacturing, however the use of fusion welding is difficult because of disparate melting points and the possibility of intermetallic compound (IMC) formation. Here, an impact welding technique, vaporizing foil actuator welding, was utilized to produce solid-state joints between AA1100-O and 1018 mild steel. The relationship between weld processing conditions, microstructure, and mechanical properties were investigated. For this purpose, the welds were annealed between 300°C and 600°C and a combination of optical and scanning electron microscopy, along with image analysis was performed to characterize the weld microstructure and monitor IMC growth. Wedge testing was applied to understand the effect of annealing on the weld fracture toughness. A numerical model incorporating the Fick's laws of diffusion, grain boundary diffusion, and grain growth kinetics was also developed to simulate the IMC growth. The heterogeneity in the original microstructure caused persistent differences in IMC growth, as initial IMC seemed to increase nucleation and growth. Simulation results indicated short circuit diffusion to be the major contributor to IMC growth since it is consistently faster then experimental IMC growths compared with the computational results that used lattice diffusion only. Wedge testing reveals increased weld toughness for modest anneals of 300°C, possibly due to homogeneity at the weld interface while avoiding IMC growth.

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“…The technology proves to be robust to join several dissimilar metals such as Al-Mg, Al-Cu, Al-Fe, Al-Ti, etc. [25][26][27][28]. However, further development and understanding of the process is needed in order to accomplish industrial adoption.…”

Section: Introductionmentioning

confidence: 99%

Joining Aluminium Alloy 5A06 to Stainless Steel 321 by Vaporizing Foil Actuators Welding with an Interlayer

Chen

Mao

et al. 2019

Metals

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Direct aluminium–stainless steel joints are difficult to create by the vaporized foil actuator welding (VFAW) method because brittle intermetallic compounds (IMCs) tend to form along the interface. The use of an interlayer as a transition layer between the two materials with vast difference in hardness and ductility was proposed as a solution to reduce the formation of the IMCs. In this work, VFAW was used to successfully weld sheet aluminium alloy 5A06 to stainless steel 321 with a 3003 aluminium alloy interlayer. Input energy levels of 6 kJ, 8 kJ, 10 kJ, and 12 kJ were used and as a trend, higher energy inputs resulted in higher impact velocities, larger weld area, and better mechanical properties. In lap-shear and peel testing, all samples failed at the interface of the interlayer and target. At 10 kJ energy input, flyer velocities up to 935 m/s, lap-shear peak load of 44 kN, and peel load of 2.15 kN were achieved. Microstructure characterization and element distribution were performed, and the results show a wavy pattern created between the flyer and interlayer which have similar properties, and the interface between the interlayer and target was dominated by element diffusion and IMCs identified mainly as FeAl3 and FeAl. The results demonstrate VFAW is a suitable joining method for dissimilar metals such as aluminium alloy and stainless steel, which has a broad and significant application prospect in aerospace and chemical industry.

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Dissimilar Impact Welding of 6111-T4, 5052-H32 Aluminum Alloys to 22MnB5, DP980 Steels and the Structure–Property Relationship of a Strongly Bonded Interface

Cited by 21 publications

References 22 publications

Dissimilar Materials Welding with a Standoff-Free Vaporizing Foil Actuator between TRIP 1180 Steel Sheets and AA5052 Alloy

Dissimilar Materials Welding with a Standoff-Free Vaporizing Foil Actuator between TRIP 1180 Steel Sheets and AA5052 Alloy

Microstructure and Fracture Toughness of an Aluminum-Steel Impact Weld and Effect of Thermal Exposure

Joining Aluminium Alloy 5A06 to Stainless Steel 321 by Vaporizing Foil Actuators Welding with an Interlayer

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