Vaporizing foil actuator welding as a competing technology to magnetic pulse welding

Hahn, Marlon; Weddeling, Christian; Taber, G. A.; Vivek, Anupam; Daehn, Glenn S.; Tekkaya, A. Erman

doi:10.1016/j.jmatprotec.2015.11.010

Cited by 39 publications

(16 citation statements)

References 32 publications

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“…The angle range for wave formation along the collision interface was proposed as 8-24 • for 3003 Al and 4130 steel [64], and 16-24 • for 3003 Al and pure Ti [61]. The recorded maximum impact velocity for VFAW was 900 m/s [66]. As for the numerical simulation, the finite element method with Eulerian formalism is a suitable way to predict the morphology of the collision interface in high-velocity impact welding [67].…”

Section: Vaporizing Foil Actuator Weldingmentioning

confidence: 99%

High-Velocity Impact Welding Process: A Review

Wang

2019

Metals

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High-velocity impact welding is a kind of solid-state welding process that is one of the solutions for the joining of dissimilar materials that avoids intermetallics. Five main methods have been developed to date. These are gas gun welding (GGW), explosive welding (EXW), magnetic pulse welding (MPW), vaporizing foil actuator welding (VFAW), and laser impact welding (LIW). They all share a similar welding mechanism, but they also have different energy sources and different applications. This review mainly focuses on research related to the experimental setups of various welding methods, jet phenomenon, welding interface characteristics, and welding parameters. The introduction states the importance of high-velocity impact welding in the joining of dissimilar materials. The review of experimental setups provides the current situation and limitations of various welding processes. Jet phenomenon, welding interface characteristics, and welding parameters are all related to the welding mechanism. The conclusion and future work are summarized.Various solid-state welding methods have been developed recently, for example, friction stir welding, explosive welding (EXW), friction welding, magnetic pulse welding (MPW), cold welding, ultrasonic welding, roll welding, pressure gas welding, resistance welding, vaporizing foil actuator welding (VFAW), gas gun welding (GGW), and laser impact welding (LIW). Among those solid-state welding methods-GGW, EXW, MPW, VFAW, and LIW-are five kinds of high-velocity impact-welding methods. They shared the same welding mechanism, but have different welding energy sources indicated by their names: high-speed gas [13], explosive [14,15], capacitor bank energy (MPW and VFAW) [16], and laser [17], respectively.High-velocity impact welding is characterized by a low welding temperature and fast welding speed. The process is conducted at room temperature. Furthermore, there is no external heat input during the welding process. Figure 1 is a schematic transient state in the welding process. After the transient force is applied on the external surface of the flyer, the flyer moves toward the target at the velocity of several hundred meters per second [18]. When the flyer collides on the target, a jet is generated at the collision point, which contains contaminants, oxide layers, and a thin layer of metals. As a result, the "clean" metals (no contaminants, oxide layers) are exposed to each other. With the transient force, they are brought within atomic distance, where the atomic bond is formed. This process is usually takes several to dozens of microseconds based on different welding processes. For example, in LIW, it usually takes less than one microsecond. In other high-velocity impact-welding processes, it takes longer than that. Metals 2019, 9, x FOR PEER REVIEW 2 of 19However, Al 7075 alloy is susceptible to hot cracking [8,9], and titanium is chemically active at high temperature [10][11][12]. Zinc-coated steel is an important structural material in automobiles. However, during the fusion-weldin...

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Section: Vaporizing Foil Actuator Weldingmentioning

confidence: 99%

High-Velocity Impact Welding Process: A Review

Wang

2019

Metals

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“…Daehn and J.C. Lippold [10], in which two metal plates were joined at low temperature under elevated impact velocity and collision angle. It shares the impact-driven solid state welding mechanism with explosive welding (EXW) [11], magnetic pulse welding (MPW) [12], and vaporizing foil actuator mechanism with explosive welding (EXW) [11], magnetic pulse welding (MPW) [12], and vaporizing foil actuator welding (VFAW) [13]. However, unlike these techniques, LIW utilizes laser induced shockwave as the driving force to accelerate the flyer plate.…”

Section: Introductionmentioning

confidence: 99%

Investigation on a Novel Laser Impact Spot Welding

Liu

Gao

Zhang

et al. 2016

Metals

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Abstract:In this paper a novel laser impact spot welding (LISW) method is described, in which a hump was formed on the flyer plate on the intended welding spot location by local pre-forming. When the flyer and base plates were placed together to perform welding, the two plates kept in contact over their entire surfaces except at the hump, where a local air gap was enough to guarantee the impact velocity and collision angle to achieve spot welding using laser pulse energy. The presented approach was implemented to join thin titanium foils to copper foils under low laser energy system. Joints with regular shapes were obtained. The microstructure in the weld interface was studied with scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS). It was found that the jetting occurred at the central region of the weld spots due to oblique impact. Wave features were observed in the weld interfaces. The impact energy was found to have significant influence on the wave's characteristics. Moreover, SEM images and EDS analysis did not show apparent element diffusion across the weld interface. Besides, the lap shearing test was used to characterize the mechanical properties of the spot welded joints.

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“…Thus, research on solid-state welding processes such as electromagnetic pulse welding or vaporizing foil actuator welding (VFAW) is being considered as an alternative 6) . Magnetic pulse welding (MPW) [7][8][9][10][11] is a process that uses the same physical principles of explosive welding (EXW); a flyer material is rapidly driven towards a target to cause an impact, so that the surface oxides are removed by jetting 12) . Although the bonding mechanism of MPW is not yet fully understood, most studies clearly observe the wavy interface shape as a representative feature 2) .…”

Section: Microstructure Evaluation Of Vaporizing Foil Actuator Welds mentioning

confidence: 99%

Microstructure Evaluation of Vaporizing Foil Actuator Welds of 1 GPa Strength Steel

Yoon

Lee

2020

Journal of Welding and Joining

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Demands for weight reduction in automobiles have been constantly increasing due to its environmental impact, leading to increased interests in light metals such as aluminum and magnesium. However, for most structural applications that require large energy absorption, implementation of high strength steel is still a pervasive solution. When the high strength steel having a high martensite fraction (DP 980) is joined by resistance spot welding, a softening zone is generated in the welds, leading to the reduction of the strength of the welds. In addition, high strength steels generally contain a large amount of carbon and alloying elements. As a result, the carbon equivalent exhibiting hardenability increases, having the welded part become weak, and making it difficult to secure the performance required by the part or the vehicle body. Vaporizing foil actuator welding (VFAW) which is one of the solid-state welding techniques utilizes a high-pressure pulse generated by the vaporization of an aluminum foil to cause high speed collision of flyer and target sheets to create solid-state bonds with negligible melting at the weld interface. So, VFAW produces joints with little to no HAZ. In this study, to examine the vaporizing foil actuator welding properties of 1 GPa grade high strength steel, microstructure analysis and hardness test were performed. The test results were compared with the resistance spot welding properties of the same material.

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Vaporizing foil actuator welding as a competing technology to magnetic pulse welding

Cited by 39 publications

References 32 publications

High-Velocity Impact Welding Process: A Review

High-Velocity Impact Welding Process: A Review

Investigation on a Novel Laser Impact Spot Welding

Microstructure Evaluation of Vaporizing Foil Actuator Welds of 1 GPa Strength Steel

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