Joining sheet aluminum AA6061-T4 to cast magnesium AM60B by vaporizing foil actuator welding: Input energy, interface, and strength

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

doi:10.1016/j.jmapro.2017.09.008

Cited by 22 publications

(12 citation statements)

References 23 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…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%

High-Velocity Impact Welding Process: A Review

Wang

2019

Metals

View full text Add to dashboard Cite

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...

show abstract

Section: Vaporizing Foil Actuator Weldingmentioning

confidence: 99%

High-Velocity Impact Welding Process: A Review

Wang

2019

Metals

View full text Add to dashboard Cite

show abstract

“…Although the range varies depending on the material pair, metallurgical bonds have been typically observed at velocities ranging between 300-1000 m/s and angles between 5-20 0 [2,[46][47][48]. Previous VFAW studies with aluminum (1XXX/2XXX/6XXX series) as the flyer material with thicknesses ranging between 0.5 mm and 2 mm, input energies between 6 kJ and 8 kJ, and standoffs of 1.6 mm and 2.5 mm have recorded impact velocities between 650 m/s to 900 m/s with successful metallurgical bonding [4,41,[49][50][51][52][53][54]. As the weld progresses the impact angle increases continuously, whereas the impact velocity decreases from a maximum at the inner edge of contact at the boundary of the unwelded zone to a minimum at the outer edge of contact, where there is no weld.…”

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

Self Cite

View full text Add to dashboard Cite

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.

show abstract

“…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. 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.…”

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

View full text Add to dashboard Cite

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.

show abstract

Joining sheet aluminum AA6061-T4 to cast magnesium AM60B by vaporizing foil actuator welding: Input energy, interface, and strength

Cited by 22 publications

References 23 publications

High-Velocity Impact Welding Process: A Review

High-Velocity Impact Welding Process: A Review

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

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

Contact Info

Product

Resources

About