Simulating the dependence of the filler wire feeding on the wire size in the hybrid metal extrusion & bonding (HYB) process

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

“…This equation takes into consideration both the pin geometry and the material properties at the tool-matrix interface. The calculated value is inserted back into the classical Rosenthal thin plate solution (Equation (4)) to obtain a new updated value for the interface temperature T int at the same position, which then is used as the basis for calculating the next estimate of q 0 from Equation (12). The process is repeated until the difference T int (i + 1) − T int (i) is less than the chosen tolerance value and convergence is obtained.…”

“…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.…”

Effect of tool size on AA6061‐T6 double‐sided friction stir welds

“…However, their welding by conventional fusion welding processes is not sometimes suitable due to crack formation during solidification, porosity, high residual stresses, large welding deformation, and formation or growth of unwanted brittle intermetallic compounds 2,3 . For aluminum and its alloys, the solid‐state joining methods offer considerable advantages over other fusion joining processes 4,5 . For example, ultrasonic welding has been implemented as a promising spot‐welding process for aluminum alloys 6 .…”

“…Explosive welding has also been adopted for the joining of similar or dissimilar metals such as steel 7 or aluminum–stainless steel welds 8 . A hybrid metal extrusion and bonding welding method has been studied by researchers that utilizes the principle of continuous extrusion as a technique to enable addition of filler wire material during welding 4,5 . Another solid‐state joining method friction stir diffusion welding has been studied using a specially designed tool that results in diffusion bonding between overlap sheets/plates 9 .…”