Interface microstructure and tensile properties of a third generation aluminium-steel butt weld produced using the Hybrid Metal Extrusion & Bonding (HYB) process

Process Modelling Applied to Aluminium-Steel Butt Welding by Hybrid Metal Extrusion and Bonding (HYB)

“…Originally, the idea was to use HYB for butt welding of aluminium plates and profiles, but over the years the method has evolved into a multi-material joining technique being particularly suitable for Al-steel welding [11,12]. This is mainly because of its low process temperature along with the use of smart tool design, which allows bonding to occur by a combination of microscale mechanical interlocking and IMC formation, where the IMC layer is in the sub-micrometre range (<1 µm) [13,14]. Moreover, the subsequent benchmarking of HYB against gas tungsten arc welding, pulsed and conventional gas metal arc welding (GMAW), laser beam welding (LBW), cold metal transfer welding (CMTW), and FSW shows that both the ultimate tensile strength and the fatigue properties of the third generation Al-steel HYB butt weld surpass those reported for similar Al-steel welds produced by the other methods [14,15].…”

“…This is mainly because of its low process temperature along with the use of smart tool design, which allows bonding to occur by a combination of microscale mechanical interlocking and IMC formation, where the IMC layer is in the sub-micrometre range (<1 µm) [13,14]. Moreover, the subsequent benchmarking of HYB against gas tungsten arc welding, pulsed and conventional gas metal arc welding (GMAW), laser beam welding (LBW), cold metal transfer welding (CMTW), and FSW shows that both the ultimate tensile strength and the fatigue properties of the third generation Al-steel HYB butt weld surpass those reported for similar Al-steel welds produced by the other methods [14,15]. At the same time, the HYB process allows butt welding to be performed at much higher travel speeds compared to FSW, without compromising the mechanical integrity of the weldment.…”

“…So far, the aptness of the HYB process for Al-steel butt welding has been demonstrated through in-depth microstructure characterisation and extensive tensile and fatigue testing [13][14][15], but no modelling of the underlying thermal and microstructural fields controlling the resulting joint properties has been conducted. Therefore, the timing is perfect for taking the HYB process technology to the next level by developing a verified quantitative understanding of the different physical phenomena involved contributing to its unique multi-material joining capabilities.…”

Effect of Pin Shape on Thermal History of Aluminum-Steel Friction Stir Welded Joint: Computational Fluid Dynamic Modeling and Validation

“…A particularly serious problem when joining metals is the formation of intermetallic compounds [15,16] that reduce the plastic properties of joints. Large differences in the properties of aluminum and ferrous alloys make the weldability window extremely limited [17,18]. Despite the simplicity of this process, understanding thermo-mechanical phenomena during welding is complicated.…”

Rapid Calculation of Residual Stresses in Dissimilar S355–AA6082 Butt Welds

“…So far, various experimental studies of the HYB process applied to similar and dissimilar metals welds were carried out in order to better understand and predict the effect of process parameters on welded materials; however, only recently was a great effort spent in the development of numerical models [23,24]. Recently, good experimental results were found for dissimilar aluminumsteel butt welds obtained by the HYB technique [25][26][27]. Numerical models were widely used in the literature to study the thermal field and residual stress arising during similar and dissimilar metal welds production; however, analytical investigations on dissimilar welded joints produced through this novel welding technique are still missing in the literature.…”