Dissimilar metals welding processes realized by vaporizing metal foils

Abstract

In high-velocity impact welding (HVIW), vaporizing foil actuator welding (VFAW) can be utilized to join dissimilar metals. In comparison with conventional welding processes, the VFAW process minimizes energy loss, enhances weld strength, and effectively mitigates issues of overheating or material deformation associated with traditional welding methods. In this study, VFAW was utilized to successfully weld three different metal materials (Cu, Al6061-T6, Q235). An accurate smoothed particle hydrodynamics (SPH) model was established based on the experimental results. The impacts of collision angle and velocity of the flyer on the interface morphology of Cu/Al6061-T6 weld were investigated using the SPH method. The experimental results show that with an increase in the collision angle from 0° to 20°, both the wavelength and amplitude of the welding interface significantly increase. The tail vortex phenomenon also becomes more pronounced with the angle of tail rotation caused by particle motion gradually increasing. But when the collision angle exceeds 20°, the wavelength and amplitude of the welding interface tend to stabilize while its influence on tail vortex phenomenon decreases. The tail rotation angle induced by particle motion continues to increase, although at a decreasing rate. When the initial collision angle is kept constant, both the wavelength and amplitude of the welding interface continue to rise with increasing collision velocity up to 900 m/s. The wake vortex phenomenon becomes more pronounced as the number of particles in the jet gradually increases.

Keywords

Vaporizing foil actuator welding (VFAW) / Dissimilar material / Numerical modeling / Smoothed particle hydrodynamics (SPH)

References

[1] ZhangQ, YePC, YangZY, et al. . Application and development of connecting technique in automobile lightweight. Nonferrous Met Process, 2019, 1: 1-9

[2] HangLJ, GuoYB. Application and development of advanced connecting technique for automobile lightweight body. MW Met Form, 2021, 4: 1-6

[3] FenFY, ChenYX. Research status of aluminum/steel dissimilar metal welding technology. Weld Technol, 2021, 1: 1-8

[4] ChenSJ, SuS, XiaoJ, et al. . Measurement of impact velocity and analysis of influencing factors of gasification impact welding fly plate. Rare Met Mater Eng, 2018, 47113439-3443

[5] ZhenYM. Explosive welding with dissimilar metals. Weld Technol, 2001, 5: 25-26

[6] WangH, WangY. High-velocity impact welding process: a review. Metals, 2019, 92144.

[7] CarvalhoG, GalvãoI, MendesR, et al. . Explosive welding of aluminium to stainless steel. J Mater Process Tech, 2018, 262: 340-349.

[8] SternA, ShribmanV, Ben-ArtzyA, et al. . Interface phenomena and bonding mechanism in magnetic pulse welding. JMEPEG, 2014, 23: 3449-3458.

[9] WangX, ShaoM, JinH, et al. . Laser impact welding of aluminum to brass. J Mater Process Technol, 2019, 269: 190-199.

[10] RenSR, MaZY, ChenLQ. Research Statusand prospect of friction stir welding and friction stir processing. Mater Rep, 2007, 1: 86-92

[11] Liu P, Li YJ, Wang J (2007) Microstructure and properties near interface zone of diffusion-bonded joint for Mg/Al dissimilar materials. Trans China Weld Inst (6):45–48, 115

[12] NassiriA, ChiniG, VivekA, et al. . Arbitrary Lagrangian–Eulerian finite element simulation and experimental investigation of wavy interfacial morphology during high velocity impact welding. Mater Des, 2015, 88: 345-358.

[13] SuS, ChenSJ, XiaoJ, et al. . Research on 5A06/0Cr18Ni10Ti gasification impact welding process based on intermediate transition layer. Acta Metall Sin, 2019, 5581041-1048

[14] ElangoE, SaravananS, RaghukandanK. Experimental and numerical studies on aluminum-stainless steel explosive cladding. J Cent South Univ, 2020, 2761742-1753.

[15] YangP, MengZH, HuangSY, et al. . Research review of magnetic pulse welding for dissimilar metals. Hot Work Technol, 2015, 3: 5-9

[16] LiJ, SchneidermanB, SongS, et al. . High strength welding of Ti to stainless steel by spot impact: microstructure and weld performance. Int J Adv Manuf Technol, 2020, 108: 1447-1461.

[17] LeeT, ZhangS, VivekA, et al. . Wave formation in impact welding: study of the Cu-Ti system. CIRP Ann, 2019, 681261-264.

[18] HahnM, WeddelingC, TaberG, et al. . Vaporizing foil actuator welding as a competing technology to magnetic pulse welding. J Mater Process Technol, 2016, 230: 8-20.

[19] SridharanN, PoplawskyJ, VivekA, et al. . Cascading microstructures in aluminum-steel interfaces created by impact welding. Mater Charact, 2019, 151: 119-128.

[20] WangDW, XiuSC. Effect of welding temperature on interfacial microstructure and properties of carbon steel/austenitic stainless steel diffusion welding joints. Acta Metall Sin, 2017, 5: 567-574.

[21] YuHP, XuZD, LiCF, et al. . Experimental research on magnetic pulse joining of 3A21aluminum Alloy-20 steel tubes. Acta Metall Sin, 2011, 2: 197-202

[22] GuptaV, LeeT, VivekA, et al. . A robust process-structure model for predicting the joint interface structure in impact welding. J Mater Process Technol, 2019, 264: 107-118.

[23] WangK, ShangSL, WangY, et al. . Unveiling non-equilibrium metallurgical phases in dissimilar Al-Cu joints processed by vaporizing foil actuator welding. Mater Des, 2020, 186. 108306

[24] EstibalsB, SallesA. Design and realisation of integrated inductor with low DC-resistance value for integrated power applications. HAIT J Sci Eng B, 2005, 25/6848-868

[25] Liu GR, Liu MB (2003) Smoothed particle hydrodynamics: a Meshfree particle method. World Scientific

RIGHTS & PERMISSIONS

Shanghai University and Periodicals Agency of Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature