Shock effects on the upper limit of the collision weld process window

Barnett, Blake; Vivek, Anupam; Daehn, Glenn

doi:10.1007/s40436-023-00472-y

Adv. Manuf.

2024

DOI: 10.1007/s40436-023-00472-y

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Shock effects on the upper limit of the collision weld process window

Blake Barnett,

Anupam Vivek,

Glenn Daehn

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Cited by 3 publications

References 36 publications

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Implementing multiple biaxial-tension proportional loading paths using double elliptical dies

He,

Hu,

et al. 2025

International Journal of Mechanical Sciences

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Implementing multiple biaxial-tension proportional loading paths using double elliptical dies

He,

Hu,

et al. 2025

International Journal of Mechanical Sciences

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Interfacial energy conversion mechanism between 3003 aluminum alloy and 321 stainless steel in vaporizing foil actuator welding process

Su,

Duan,

et al. 2024

Sci Rep

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Conventional welding methods encounter significant challenges, including poor weldability, low joint strength, and the formation of brittle intermetallic compounds, primarily due to the substantial disparities in the physical and chemical properties of aluminum and iron. To mitigate these issues, the vaporizing foil actuator welding (VFAW) process has emerged as a highly promising solid-phase welding technology, particularly suitable for joining dissimilar metals with pronounced differences in properties, such as aluminum alloys and stainless steels. The present study provides an innovative quantitative analysis of the interfacial impact energy conversion mechanisms within the VFAW process. The analysis reveals that the energy responsible for accelerating the flyer workpiece comprises burst vaporization energy ( ) and continuous vaporization energy ( ), with identified as the primary energy source, contributing approximately 65–80% of the total energy required for acceleration. Further examination elucidates the mechanisms underlying heat generation and transfer during the interface collision. The investigation identifies the formation of an overheating zone at the interface, attributed to the combined effects of plastic deformation energy and adiabatic shear energy within the flyer workpiece. Consequently, the interface temperature can rise significantly, reaching up to 1394 K, with impact velocities as high as 925 m/s. The analyses contribute to establishing a theoretical foundation for understanding the interface bonding mechanisms characteristic of the vaporizing foil actuator welding method.

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Lagrangian Finite Element Model Formulation and Experimental Validation of the Laser Impact Weld Process for Ti/Brass Joining

Caruso,

Sanguedolce,

Serratore

et al. 2024

JMMP

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Information on the flyer deformation during laser impact welding (LIW) is an important aspect to consider when high reliability of the welded components is required. For this reason, accurate numerical models simulating thermal and mechanical aspects are needed. In the present work, the cross-section morphology during LIW of Ti/Brass joints at varying laser pulse energies is modeled by a 2D finite element (FE) model. A hydrodynamic plasma pressure model able to describe the evolution of the pressure load step by step, taking into account the progressive deformation of the flyer, was implemented. Hence, this paper proposes an alternative method to the conventional node concentrated forces or predefined velocity as flyer boundary conditions. The levels of the equivalent plastic strain (PEEQ), shear stress, and critical flyer velocity at the collision point were used as reference parameters to predict the success of the welding bond, distinguishing the welded area from the unwelded area. The model was validated by comparison with the experimental data, which showed the effectiveness of the proposed FE code in predicting the cross-section morphology of the welded materials. Moreover, practical industrial information such as variation in the flyer impact velocity, collision angle, and process temperatures was predicted by varying the process laser pulse energy according to the basic principle of the process.

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Shock effects on the upper limit of the collision weld process window

Cited by 3 publications

References 36 publications

Implementing multiple biaxial-tension proportional loading paths using double elliptical dies

Implementing multiple biaxial-tension proportional loading paths using double elliptical dies

Interfacial energy conversion mechanism between 3003 aluminum alloy and 321 stainless steel in vaporizing foil actuator welding process

Lagrangian Finite Element Model Formulation and Experimental Validation of the Laser Impact Weld Process for Ti/Brass Joining

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