Investigation of melting phenomena in solid-state welding processes

Nassiri, A.; Abke, Tim; Daehn, Glenn S.

doi:10.1016/j.scriptamat.2019.04.021

Cited by 44 publications

(13 citation statements)

References 24 publications

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“…The center or unwelded region between the top and bottom welds is the result of the zero angle of impact between the flyer and target sheets [55]. Although, VFAW an impact welding technique falls under the realm of solid-state welding technology, evidence of localised melting has been found both experimentally and through numerical simulations [49,[56][57][58][59][60]. Based on the combination of the impact velocity and angle, temperatures above melting point of joining members can be reached locally, leading to localised melting.…”

Section: Weld Mechanical Propertiesmentioning

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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Section: Weld Mechanical Propertiesmentioning

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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“…7) Nassiri et al using both experimental analysis and numerical simulations investigated the melting phenomena at the vaporizing foil actuation welded Al/Fe joint interface. 8) They reported that the formation of microstructural defects within IML were deduced as the combined result of ultra-fast melting followed by rapid cooling. Bataev et al also using SPH method calculated the temperature distribution at the explosive welded steel/steel joint interface and presented that due to the effect of high pressures, the melting temperature of steel significantly increased.…”

Section: Introductionmentioning

confidence: 99%

Experimental and Numerical Analyses of Wavy Interface Formation and Local Melting Phenomena at the Magnetic Pulse Welded Al/Fe Joint Interface

Muraishi

Kumai

2021

Mater. Trans.

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A 1050-O aluminum plate and a low carbon steel (SPCC) plate were seam welded by magnetic pulse welding (MPW). Experimental and numerical analysis methods were combined to investigate the wavy interface formation and local melting phenomena at the Al/Fe joint interface. The metallographic observation results showed that Al/Fe joint interface presents a trigger-like wave shape with two types of intermediate layers intermittently formed at the interface. Collision angle between two plates and impact velocity of Al sheet driven by electromagnetic force was numerically solved by coupled mechanical and electromagnetic fields analysis. The metal jet emission behavior, wavy interface formation process and the temperature change during MPW collision process was analyzed by SPH method. The numerical results showed that the temperature near the interface exceeds the melting point of both Al and Fe at extremely high pressure, which leads to the formation of a local melting zone (LMZ) where Al and Fe were mixed in melted state. The numerically reproduced wavy interface morphology showed a good consistency with the experimentally observed results.

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“…Flyer velocity and wavy interface morphology were also studied. Nassiri et al [3] studied solid-state welding processes by combined numerical simulations, diffusion calculations, and interfacial characterisation techniques. Determination of the relations between the development of defects within the joining area and melting phenomena was concluded.…”

Section: Introductionmentioning

confidence: 99%

“…Many of the latest MPW studies have shown evidence of melted and rapidly cooled regions along the joint interface, e.g., amorphous structures that can be attributed to rapid solidification with cooling rates in the magnitude of 10 7 K•s −1 . Recrystallised nanometric grain size, as well as localised melting in the range of micron-sized "pockets" were observed by several studies [3,7,[15][16][17]. Bellmann et al [18] examined the cloud of CoP particles, which is expelled as an outcome of the high-speed impact between the two metals.…”

Section: Introductionmentioning

confidence: 99%

“…The latest descriptions of MPW joints have several common aspects, e.g., regions in the form of thin layers and/or "pockets" of melted and rapidly resolidified material were frequently observed. This means, according to some researchers, that local "liquid-state welding" can additionally be considered an active joining mechanism for the MPW process, which is basically regarded as a solid-state technique [3,7]. If the local temperatures are too low before solidification has been completed, the joint quality may be lower than expected.…”

Section: Introductionmentioning

confidence: 99%

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On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions

Nahmany

Shribman

Levi³

et al. 2020

Metals

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This novel research aims to examine the macro and microstructural bonding region development during magnetic pulse welding (MPW) of dissimilar additive manufactured (AM) laser powder-bed fusion (L-PBF) AlSi10Mg rod and AA6060-T6 wrought tube, using both optimal- and high-energy welding conditions. For that purpose, various joint characterisation methods were applied. It is demonstrated that high-quality hermetic welds are achievable with adjusted MPW process parameters. The macroscale analysis has shown that the joint interfaces are deformed to a waveform shape; the interface is starting relatively planar, with waves forming and growing in the welding direction. The observed thickening of the flyer’s wall after welding is the result of its diametral inward deformation, taking place during the process. A slight increase in microhardness was adjacent to the faying interfaces; a higher increase was measured on the AlSi10Mg material side, while a smaller one was observed on the AA6060 side. Along the wavy interfaces, resolidified “pockets” of material or occasionally discontinuous short layers exhibiting different morphologies, were detected. The jet residues are typically located towards the end of the weld, confirming a temperature rise that exceeds the melting temperature of both alloys. Far from the weld zone, extremely thin-film deposits were clearly observed on the inner flyer surfaces. The formation of isolated Si particles and thin-film deposits may point out that the local increase in temperatures leads to melting or even evaporation vaporisation of superficial layers from the colliding parts. It is worth noting that this type of jet residue was discovered for the first time in the present research. The current research work is expected to provide an understanding of weld formation mechanisms of additively manufactured parts to conventional wrought parts conforming to existing wrought/wrought weld knowledge.

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Investigation of melting phenomena in solid-state welding processes

Cited by 44 publications

References 24 publications

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

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

Experimental and Numerical Analyses of Wavy Interface Formation and Local Melting Phenomena at the Magnetic Pulse Welded Al/Fe Joint Interface

On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions

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