On the microstructure and the origin of intermetallic phase seams in magnetic pulse welding of aluminum and steel

Böhme, Marcus; Sharafiev, Semen; Schumacher, E. E.; Böhm, Stefan; Wagner, Martin F.‐X.

doi:10.1002/mawe.201900034

Cited by 8 publications

(1 citation statement)

References 16 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…MPW tests were performed in vacuum, with diverse collision conditions to suppress the interaction with air, for a better-quality process monitoring. Böhme et al [19] reported on the microstructure of aluminium-steel specimens produced by MPW. As one layer could be identified as Al solid solution, a very thin layer close to the steel side of the compound was found.…”

Section: Introductionmentioning

confidence: 99%

On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions

Nahmany

Shribman

Levi³

et al. 2020

Metals

View full text Add to dashboard Cite

This novel research aims to examine the macro and microstructural bonding region development during magnetic pulse welding (MPW) of dissimilar additive manufactured (AM) laser powder-bed fusion (L-PBF) AlSi10Mg rod and AA6060-T6 wrought tube, using both optimal- and high-energy welding conditions. For that purpose, various joint characterisation methods were applied. It is demonstrated that high-quality hermetic welds are achievable with adjusted MPW process parameters. The macroscale analysis has shown that the joint interfaces are deformed to a waveform shape; the interface is starting relatively planar, with waves forming and growing in the welding direction. The observed thickening of the flyer’s wall after welding is the result of its diametral inward deformation, taking place during the process. A slight increase in microhardness was adjacent to the faying interfaces; a higher increase was measured on the AlSi10Mg material side, while a smaller one was observed on the AA6060 side. Along the wavy interfaces, resolidified “pockets” of material or occasionally discontinuous short layers exhibiting different morphologies, were detected. The jet residues are typically located towards the end of the weld, confirming a temperature rise that exceeds the melting temperature of both alloys. Far from the weld zone, extremely thin-film deposits were clearly observed on the inner flyer surfaces. The formation of isolated Si particles and thin-film deposits may point out that the local increase in temperatures leads to melting or even evaporation vaporisation of superficial layers from the colliding parts. It is worth noting that this type of jet residue was discovered for the first time in the present research. The current research work is expected to provide an understanding of weld formation mechanisms of additively manufactured parts to conventional wrought parts conforming to existing wrought/wrought weld knowledge.

show abstract

Section: Introductionmentioning

confidence: 99%

On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions

Nahmany

Shribman

Levi³

et al. 2020

Metals

View full text Add to dashboard Cite

show abstract

Improving and monitoring the magnetic pulse welding process between dissimilar metals

et al. 2020

View full text Add to dashboard Cite

Conventional fusion welding of dissimilar metals is often limited due to the different thermo-physical properties of the joining partners. In consequence, brittle intermetallic phases (IMC) can occur. Utilizing a pressure welding process like magnetic pulse welding (MPW) reduces the risk of IMCs significantly. Furthermore, this welding process has an outstanding short process duration in the range of a few microseconds, which makes it predestined for mass production. At the same time, this advantage challenges the process observation, inline-quality assurance hardware, and the design of the tool coils. The paper presents two strategies for reducing the energy input during MPW to increase the tool coil lifetime. The first approach, the introduction of a reactive nickel interlayer between steel and aluminum, leads to a significant welding energy reduction. Compared to aluminum samples joined by laser welding, the load-bearing capability of the resulting hybrid MPW driveshaft samples is higher in static torsion tests and similar in cyclic tests. The second approach is based on a novel process monitoring system that helps to analyze the characteristic light emission. The capability of the process monitoring system is presented on the example of a MPW-joined multimaterial part made of stainless steel, aluminum, and copper.

show abstract

Microstructure and formation mechanism of the transition layer at the interface of Al–Cu EMPW joint

Zhou,

Li,

Chen

et al. 2024

Journal of Materials Research and Technology

View full text Add to dashboard Cite

On the microstructure and the origin of intermetallic phase seams in magnetic pulse welding of aluminum and steel

Cited by 8 publications

References 16 publications

On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions

On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions

Improving and monitoring the magnetic pulse welding process between dissimilar metals

Microstructure and formation mechanism of the transition layer at the interface of Al–Cu EMPW joint

Contact Info

Product

Resources

About