Interface Formation during Collision Welding of Aluminum
Benedikt Niessen,
Eugen Schumacher,
Jörn Lueg-Althoff,
Jörg Bellmann,
Marcus Böhme,
Stefan Böhm,
A. Erman Tekkaya,
Eckhard Beyer,
Christoph Leyens,
Martin Franz-Xaver Wagner,
Peter Groche
Affiliations
Benedikt Niessen
Institute for Production Engineering and Forming Machines—PtU, The Technical University (TU) of Darmstadt, Otto-Berndt-Strasse 2, 64287 Darmstadt, Germany
Eugen Schumacher
Department for Cutting and Joining Manufacturing Processes—tff, The University of Kassel, Kurt-Wolters-Str. 3, 34125 Kassel, Germany
Jörn Lueg-Althoff
Institute of Forming Technology and Lightweight Components, TU Dortmund University, Baroper Str. 303, 44227 Dortmund, Germany
Jörg Bellmann
Institute of Manufacturing Science and Engineering, Technische Universität Dresden, George-Baehr-Str. 3c, 01062 Dresden, Germany
Marcus Böhme
Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Straße 73, 09125 Chemnitz, Germany
Stefan Böhm
Department for Cutting and Joining Manufacturing Processes—tff, The University of Kassel, Kurt-Wolters-Str. 3, 34125 Kassel, Germany
A. Erman Tekkaya
Institute of Forming Technology and Lightweight Components, TU Dortmund University, Baroper Str. 303, 44227 Dortmund, Germany
Eckhard Beyer
Institute of Manufacturing Science and Engineering, Technische Universität Dresden, George-Baehr-Str. 3c, 01062 Dresden, Germany
Institute of Materials Science and Engineering, Chemnitz University of Technology, Erfenschlager Straße 73, 09125 Chemnitz, Germany
Peter Groche
Institute for Production Engineering and Forming Machines—PtU, The Technical University (TU) of Darmstadt, Otto-Berndt-Strasse 2, 64287 Darmstadt, Germany
Collision welding is a high-speed joining technology based on the plastic deformation of at least one of the joining partners. During the process, several phenomena like the formation of a so-called jet and a cloud of particles occur and enable bond formation. However, the interaction of these phenomena and how they are influenced by the amount of kinetic energy is still unclear. In this paper, the results of three series of experiments with two different setups to determine the influence of the process parameters on the fundamental phenomena and relevant mechanisms of bond formation are presented. The welding processes are monitored by different methods, like high-speed imaging, photonic Doppler velocimetry and light emission measurements. The weld interfaces are analyzed by ultrasonic investigations, metallographic analyses by optical and scanning electron microscopy, and characterized by tensile shear tests. The results provide detailed information on the influence of the different process parameters on the classical welding window and allow a prediction of the different bond mechanisms. They show that during a single magnetic pulse welding process aluminum both fusion-like and solid-state welding can occur. Furthermore, the findings allow predicting the formation of the weld interface with respect to location and shape as well as its mechanical strength.
