Process window acquisition for impact welding processes

Groche, Peter; Becker, Marco; Pabst, Christian

doi:10.1016/j.matdes.2017.01.013

Cited by 37 publications

(23 citation statements)

References 16 publications

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“…In this area, no welding was observed, although the collision front velocity is above the lower limit and below the upper welding boundary of 5,100 m/s, defined by the speed of sound of the involved materials. These finding is in good correlation with literature [19] and will be explained by the observations in the next chapter.…”

Section: Monitoring Of the Axial Flyer Deformationsupporting

confidence: 90%

Measurement of Collision Conditions in Magnetic Pulse Welding Processes

Bellmann¹,

Beyer²,

Lueg‐Althoff³

et al. 2017

JPSA

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MPW (magnetic pulse welding) is a solid state joining technology that allows for the generation of strong metallic bonds, even between dissimilar metals. Due to the absence of external heat, critical intermetallic phases can largely be avoided. In this process, Lorentz forces are utilized for the rapid acceleration of at least one of the two metallic joining partners leading to the controlled high velocity impact between them. The measurement of the collision conditions and their targeted manipulation are the key factors of a successful process development. Optical measuring techniques are preferred, since they are not influenced by the prevalent strong magnetic field in the vicinity of the working coil. In this paper, the characteristic high velocity impact flash during MPW was monitored and evaluated using phototransistors in order to measure the time of the impact. The results are in good accordance with the established PDV (photon Doppler velocimetry) and show a good repeatability. Furthermore, the collision front velocity was investigated using adapted part geometries within a series of tests. This velocity component is one of the key parameters in MPW; its value decreases along the weld zone. With the help of this newly introduced measurement tool, the magnetic pressure distribution or the joining geometry can be adjusted more effectively.

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Section: Monitoring Of the Axial Flyer Deformationsupporting

confidence: 90%

Measurement of Collision Conditions in Magnetic Pulse Welding Processes

Bellmann¹,

Beyer²,

Lueg‐Althoff³

et al. 2017

JPSA

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“…For example, 6. Process window of aluminum by collision angle over impact velocity [11]. 49 a lower gradient for the upper line is observed in spot tests with aluminum of higher strain hardening.…”

Section: Investigation On the Process Windows And The Influencing Facmentioning

confidence: 91%

“…A script in MATLAB MathWorks measures the collision angle β in each high-speed image by edge detection. Using β and the resulting impact velocity v imp , the collision point velocity v c can be determined from the following trigonometric relation [11]:…”

Section: Model Test Rig and Process Observationmentioning

confidence: 99%

“…The test rig described above permits an in-depth examination of the collision welding between specimens of different material combinations. In a previous research the collision welding behavior of commercially pure aluminum (Al 99.5 %, yield strength: 105 MPa, thickness: 2 mm) is shown [11]. In order to investigate the influence of the material on the process window, experiments with copper (Cu 99.9 %, yield strength: 202 MPa) are performed and compared to the ones with aluminum.…”

Section: Determination Of Process Windowsmentioning

confidence: 99%

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Process boundaries of collision welding at low energies

Groche

Niessen

Pabst

2019

Materialwissenschaft Werkst

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Collison welding is a promising material-closed joining process that enables bonds with various advantages. It is already used as explosion welding to produce clad materials that cannot be joined otherwise. Other collision welding processes as electromagnetic pulse welding do not contain that amount of energy, but they can be used in mass production. In order to achieve a high process and product reliability, the process has to be designed accurately. But the process boundaries are not yet completely understood. In this paper, process windows for aluminium and copper joints, produced by a model test rig, are compared. Additionally, high speed observation and micro sections are used to enhance the knowledge about process boundaries and the influence of the jet. Keywords: Collision welding / process window / high speed observation / jet / electromagnetic pulse welding Das Kollisionsschweißen ist ein vielversprechendes stoffschlüssiges Fügeverfahren, das Verbindungen mit vielfältigen Vorteilen ermöglicht. Es wird bereits lange als Explosionsschweißverfahren eingesetzt, um plattierte Halbzeuge herzustellen, die sonst nicht gefügt werden können. Andere Kollisionsschweißverfahren wie das elektromagnetische Pulsschweißen verfügen nicht über diese Energiemenge, können aber in der Massenproduktion eingesetzt werden. Um eine hohe Prozess-und Produktzuverlässigkeit zu erreichen, muss allerdings der Prozess genau ausgelegt werden. Allerdings sind die Prozessgrenzen noch nicht vollständig verstanden. In diesem Beitrag werden Prozessfenster für Aluminium-und Kupferverbindungen verglichen, die auf einem Modellversuchsstand erzeugt werden. Darüber hinaus werden Hochgeschwindigkeitsbeobachtungen und Mikroschliffe genutzt, um das Wissen über die Prozessgrenzen und den Einfluss des Jets zu erweitern. Schlüsselwörter: Kollisionsschweißen / Prozessfenster / Hochgeschwindigkeitsbeobachtung / Jet / elektromagnetisches Pulsschweißen

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“…The measurement of the collision conditions enabling quantitative determination of the weldability window is relatively complicated under normal conditions due to the high velocity, small distance, blast related phenomena (shock wave in air, detonation products) and shock wave in the welded metals. The poor observability of the welding process caused by high velocities is described in [8]. Some attempts have been reported using gas gun [9] or rotating rig [10,11] for acceleration of small test samples and a Photonic Doppler Velocimetry (PDV) was used for collision ve-locity determination in magnetic pulse welding [12,13] enabling studies of the welding mechanism.…”

Section: Introductionmentioning

confidence: 99%

Experimental Determination of Acceleration of Explosively Driven Metal by Photonic Doppler Velocimetry in the Process of Explosive Welding

Kučera

Anastacio

Nesvadba

et al. 2018

Propellants Explo Pyrotec

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Two important parameters reflect in the quality of the interface of two explosively welded metal plates – impact velocity and collision angle. Both parameters can be determined from the knowledge of velocity history of the accelerated surface. A suitable measurement methodology that would allow in‐situ determination of the course of acceleration at a technological scale experiments is however not yet available. One of the emerging options enabling such measurements is Photonic Doppler Velocimetry (PDV). This paper focuses on the issues observed during measurement of metal plate acceleration in explosive welding using this technique. A well‐known combination in which copper plate is accelerated by detonation and welded to a steel baseplate was chosen for small scale experiments. The methodology was further employed at a large scale technological tests were two different steel plates were joined by detonation. The PDV proved to be successful in determination of the entire velocity history and provides unprecedented insight into the welding process. The knowledge of the velocity time history enables optimization of the impact velocity and collision angle without having to modify the explosive composition. A methodology of velocity measurement of the entire velocity profile of accelerated plate and its collision velocity during metal welding was developed. In addition, we are proposing a new way of optimizing welding parameters based on the exact velocity and thus a collision angle calculation.

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Process window acquisition for impact welding processes

Cited by 37 publications

References 16 publications

Measurement of Collision Conditions in Magnetic Pulse Welding Processes

Measurement of Collision Conditions in Magnetic Pulse Welding Processes

Process boundaries of collision welding at low energies

Experimental Determination of Acceleration of Explosively Driven Metal by Photonic Doppler Velocimetry in the Process of Explosive Welding

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