Microstructural and mechanical characterisation of a second generation hybrid metal extrusion &amp; bonding aluminium-steel butt joint

Bergh, Tina; Sandnes, Lise; Johnstone, Duncan N.; Grong, Ø.; Berto, Filippo; Holmestad, Randi; Midgley, Paul A.; Vullum, Per Erik

doi:10.1016/j.matchar.2020.110761

Cited by 10 publications

(8 citation statements)

References 54 publications

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“…The results of the two models showed good agreement despite some small differences in the weld line where the Rosenthal's solution (asymptotic) overestimates the temperature field. However, it is known that no melting occurs during the process [26]; therefore, the latent heat was not considered in the simulations. Moreover, since the analytical solution was considered uncoupled for aluminum and steel, a discontinuity at the interface is observed.…”

Section: Temperature Resultsmentioning

confidence: 99%

“…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.…”

Section: Introductionmentioning

confidence: 99%

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

et al. 2021

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An analytical model is proposed to rapidly capture the thermal and residual stresses values induced by the hybrid metal extrusion and bonding (HYB) process on dissimilar-metal butt-welded joints. The power input for two welding velocities is first assessed using a thermal–mechanical model solved by a heat generation routine written in MATLAB code. Subsequently, the obtained temperature history is used as input to solve the equilibrium and compatibility equations formulated to calculate the thermal and residual stresses. To verify the soundness of the analytical approach, a Finite Element numerical model of the entire process is carried out and results are compared with those coming from the proposed rapid method. It is found that the degree of accuracy reached by the analytical model is excellent, especially considering the tremendous time reduction when compared to that characterizing the standard numerical approach.

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Section: Temperature Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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

et al. 2021

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“…The extruded aluminum successfully penetrates pores (of micron size) of the inner surface of the steel hole. The two materials were joined by a micro-scale mechanical interlock mechanism between the extruded aluminum and the steel [26]. The interface line between the two materials is clearly observed.…”

Section: Joint's Scanning Electron Microscopic and X-ray Diffraction ...mentioning

confidence: 99%

Friction Spot Lap Joining of Aluminum Alloy AA6061 to Pre-Holed and Threaded Carbon Steel AISI 1006

Ibrahim

Hussein

Jadee

2022

International Journal of Applied Mechanics and Engineering

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This work addresses to joining aluminum alloy AA6061 to carbon steel AISI 1006 sheets using the friction spot joining technique. The steel sheets were pre-holed and threaded with an internal M6 thread. The joining process was carried out by extruding the aluminum through the steel hole and thread using a rotating tool with friction between the tool and aluminum. Three process parameters were used: pre-heating time, rotating speed and plunging depth of the tool, with four levels for each parameter. The results indicated that the two materials joined by a micro-scale mechanical interlock at an interface line of a width ranged between 0.7 to ~ 2.5 mm. The joint’s shear force reached a minimum and maximum value of 2000 and 2500 N, respectively. The plunging depth was the most effective factor affecting the amount of the extruded aluminum and the joint’s shear force.

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“…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].…”

Section: Introductionmentioning

confidence: 99%

“…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.…”

Section: Introductionmentioning

confidence: 99%

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

Leoni

Grong

Celotto

et al. 2022

Metals

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In the present investigation, the numerical code WELDSIM is used to simulate butt welding of 4 mm thick plates of S355 steel and AA6082-T6 by Hybrid Metal Extrusion and Bonding (HYB). This is a new solid state joining process using continuous extrusion as a technique to enable aluminium filler metal additions. In WELDSIM, the finite element heat flow model is coupled to a frictional heating model, an isokinetic diffusion model for the interfacial intermetallic compound (IMC) formation and a nanostructure model for simulating reversion and re-precipitation of hardening phases inside the aluminium part of the joints during welding and subsequent natural ageing. The HYB process model is validated by comparison with experimental data obtained from in-situ thermocouple measurements and hardness testing carried out on three different Al-steel butt welds. Furthermore, scanning electron microscope examinations of the Al-steel interfaces have been conducted to check the predicted power of the IMC diffusion model. It is concluded that the process model is sufficiently relevant and comprehensive to be used in simulations of both the thermal, microstructure, and strength evolutions fields in these dissimilar butt welds. Some practical applications of the process model are described toward the end of the article, where particularly its potential for optimising the load-bearing capacity of the joints, is highlighted.

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Microstructural and mechanical characterisation of a second generation hybrid metal extrusion & bonding aluminium-steel butt joint

Cited by 10 publications

References 54 publications

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

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

Friction Spot Lap Joining of Aluminum Alloy AA6061 to Pre-Holed and Threaded Carbon Steel AISI 1006

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

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