Finite element modelling of the filler wire feeding in the hybrid metal extrusion & bonding (HYB) process

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

“…During extrusion and joining, the torque acting on the drive spindle may vary, depending on the experimental conditions. Still, the HYB control system guarantees a constant spindle rotational speed [14]. Hence, the spindle rotational speed, as opposed to the torque, is a process variable that can be fixed prior to the welding operation and used to control the FM addition.…”

“…Recently, a new solid-state joining method for metals and alloys has been developed, known as the Hybrid Metal Extrusion and Bonding (HYB) process [10][11][12][13][14]. This method, which is based on the principles of continuous extrusion, allows joining to be performed using aluminium filler metal (FM) additions similar to that done in gas metal arc welding (GMAW) but without any melting involved.…”

“…Metallic bonding between the FM and the BM occurs as a result of these two contributions along with oxide dispersion [10,11]. By taking into consideration the mass balance involved, the extrudate flow rate can be adjusted (by using the rotational speed of the drive spindle as the main process variable) in such a way that the groove between the plates is filled with solid aluminium in a continuous manner [10][11][12][13][14]. Since HYB is based on the principles of continuous extrusion, it will differ from traditional friction stir welding (FSW), although some similarities exist.…”

Fatigue properties of AA6060‐T6 butt welds made by hybrid metal extrusion & bonding

“…The 2-mm AA6060-T6 HYB butt weld referred to above was produced in HyBond's research laboratory at the Norwegian University of Science and Technology (NTNU). Since a full description of the pilot HYB machine at NTNU along with the experimental setup and applied welding procedure have been reported elsewhere, 24,25,32,33 only a brief summary is given below.…”

“…22 It is based on the principles of continuous extrusion, where the so-called PinPoint extruder is the core of the invention. [23][24][25] In the HYB process, favourable features of FSW and gas metal arc welding (GMAW) are combined by allowing solid state joining through aluminium filler metal (FM) additions along with the use of an appropriate groove or joint design. [26][27][28][29][30] For example, in butt joining of aluminium plates and profiles using HYB, groove cross-sections up to 20 mm 2 can be filled with solid aluminium in one pass, ensuring metallic bonding between the FM and the BM by a combination of oxide dispersion and severe plastic deformation.…”