Interfacial microstructures and mechanical property of vaporizing foil actuator welding of aluminum alloy to steel

Chen, Shuhai; Daehn, Glenn S.; Vivek, Anupam; Liu, Bert; Hansen, S.; Huang, Jihua; Lin, Sanbao

doi:10.1016/j.msea.2016.02.040

Cited by 49 publications

(17 citation statements)

References 24 publications

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“…By studying the effect of the impact angle on metallurgical bonding, the target was designed with grooves, which have different angles. The angle range for wave formation along the collision interface was proposed as 8-24 • for 3003 Al and 4130 steel [64], and 16-24 • for 3003 Al and pure Ti [61]. The recorded maximum impact velocity for VFAW was 900 m/s [66].…”

Section: Vaporizing Foil Actuator Weldingmentioning

confidence: 94%

“…Vivek pointed out that the aluminum foil provided better mechanical impulse than copper foil through its rapid vaporization. Materials such as steel, aluminum, titanium, copper, magnesium, bulk metallic glass, etc., have been successfully welded with VFAW [61][62][63][64][65]. The original experimental setups in VFAW were similar to those used in EXW.…”

Section: Vaporizing Foil Actuator Weldingmentioning

confidence: 99%

See 1 more Smart Citation

High-Velocity Impact Welding Process: A Review

Wang

2019

Metals

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High-velocity impact welding is a kind of solid-state welding process that is one of the solutions for the joining of dissimilar materials that avoids intermetallics. Five main methods have been developed to date. These are gas gun welding (GGW), explosive welding (EXW), magnetic pulse welding (MPW), vaporizing foil actuator welding (VFAW), and laser impact welding (LIW). They all share a similar welding mechanism, but they also have different energy sources and different applications. This review mainly focuses on research related to the experimental setups of various welding methods, jet phenomenon, welding interface characteristics, and welding parameters. The introduction states the importance of high-velocity impact welding in the joining of dissimilar materials. The review of experimental setups provides the current situation and limitations of various welding processes. Jet phenomenon, welding interface characteristics, and welding parameters are all related to the welding mechanism. The conclusion and future work are summarized.Various solid-state welding methods have been developed recently, for example, friction stir welding, explosive welding (EXW), friction welding, magnetic pulse welding (MPW), cold welding, ultrasonic welding, roll welding, pressure gas welding, resistance welding, vaporizing foil actuator welding (VFAW), gas gun welding (GGW), and laser impact welding (LIW). Among those solid-state welding methods-GGW, EXW, MPW, VFAW, and LIW-are five kinds of high-velocity impact-welding methods. They shared the same welding mechanism, but have different welding energy sources indicated by their names: high-speed gas [13], explosive [14,15], capacitor bank energy (MPW and VFAW) [16], and laser [17], respectively.High-velocity impact welding is characterized by a low welding temperature and fast welding speed. The process is conducted at room temperature. Furthermore, there is no external heat input during the welding process. Figure 1 is a schematic transient state in the welding process. After the transient force is applied on the external surface of the flyer, the flyer moves toward the target at the velocity of several hundred meters per second [18]. When the flyer collides on the target, a jet is generated at the collision point, which contains contaminants, oxide layers, and a thin layer of metals. As a result, the "clean" metals (no contaminants, oxide layers) are exposed to each other. With the transient force, they are brought within atomic distance, where the atomic bond is formed. This process is usually takes several to dozens of microseconds based on different welding processes. For example, in LIW, it usually takes less than one microsecond. In other high-velocity impact-welding processes, it takes longer than that. Metals 2019, 9, x FOR PEER REVIEW 2 of 19However, Al 7075 alloy is susceptible to hot cracking [8,9], and titanium is chemically active at high temperature [10][11][12]. Zinc-coated steel is an important structural material in automobiles. However, during the fusion-weldin...

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Section: Vaporizing Foil Actuator Weldingmentioning

confidence: 94%

Section: Vaporizing Foil Actuator Weldingmentioning

confidence: 99%

High-Velocity Impact Welding Process: A Review

Wang

2019

Metals

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“…ALE was deemed incapable of mimicking material vorticities. Chen et al [19] machined slanted grooves in 6.3 mm thick steel plates at different angles ranging from 8 to 28 degrees and joined them to 0.508 mm thick aluminum flyers using VFAW. They used this technique to control the impact angle, and thus obtained various morphologies at the weld interface.…”

Section: Vaporizing Foil Actuator Weldingmentioning

confidence: 99%

Simulation and Experimental Comparison of Laser Impact Welding with a Plasma Pressure Model

Sadeh

Gleason

Hatamleh

et al. 2019

Metals

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In this study, spatial and temporal profiles of an Nd-YAG laser beam pressure pulse are experimentally characterized and fully captured for use in numerical simulations of laser impact welding (LIW). Both axisymmetric, Arbitrary Lagrangian-Eulerian (ALE) and Eulerian dynamic explicit numerical simulations of the collision and deformation of the flyer and target foils are created. The effect of the standoff distance between the foils on impact angle, velocity distribution, springback, the overall shape of the deformed foils, and the weld strength in lap shear tests are investigated. In addition, the jetting phenomenon (separation and ejection of particles at very high velocities due to high-impact collision) and interlocking of the foils along the weld interface are simulated. Simulation results are compared to experiments, which exhibit very similar deformation and impact behaviors. In contrast to previous numerical studies that assume a pre-defined deformed flyer foil shape with uniform initial velocity, the research in this work shows that incorporation of the actual spatial and temporal profiles of the laser beam and modeling of the corresponding pressure pulse based on a laser shock peening approach provides a more realistic prediction of the LIW process mechanism.

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“…The generated explosive pressure sharply pushes the flyer sheet with substantially high velocity, and it distributes along the welding interface, which tends to induce an oblique angle between the target and flyer sheets as shown in Figure 1c. This explosive pressure ejects oxides and other contaminants on the interface with leaving behind fresh metal surfaces, which leads to the formation of a metallic bond between the two sheets by attaching clean metallic surfaces [25,26]. Chen et al [26] and Liu et al [27,28] have demonstrated the VFAW process to weld dissimilar materials such as various grades of steel with light-weight alloys including aluminum and magnesium alloys.…”

Section: Introductionmentioning

confidence: 99%

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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Interfacial microstructures and mechanical property of vaporizing foil actuator welding of aluminum alloy to steel

Cited by 49 publications

References 24 publications

High-Velocity Impact Welding Process: A Review

High-Velocity Impact Welding Process: A Review

Simulation and Experimental Comparison of Laser Impact Welding with a Plasma Pressure Model

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

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