Research Papers

Flyer Thickness Effect in the Impact Welding of Aluminum to Steel

[+] Author and Article Information
Taeseon Lee

Department of Materials
Science and Engineering,
The Ohio State University,
Columbus, OH 43210
e-mail: lee.7272@osu.edu

Shunyi Zhang, Brad Kinsey

Mechanical Engineering Department,
The University of New Hampshire,
Durham, NH 03824

Anupam Vivek, Glenn Daehn

Department of Materials
Science and Engineering,
The Ohio State University,
Columbus, OH 43210

1Corresponding author.

Manuscript received May 9, 2018; final manuscript received August 13, 2018; published online September 17, 2018. Assoc. Editor: Wayne Cai.

J. Manuf. Sci. Eng 140(12), 121002 (Sep 17, 2018) (7 pages) Paper No: MANU-18-1324; doi: 10.1115/1.4041247 History: Received May 09, 2018; Revised August 13, 2018

Impact welding is a material processing technology that enables metallurgical bonding in the solid state using a high-speed oblique collision. In this study, the effects of thickness of the flier and collision angle on weld interface morphology were investigated through the vaporizing foil actuator welding (VFAW) of AA1100-O to AISI 1018 Steel. The weld interfaces at various controlled conditions show wavelength increasing with the flier thickness and collision angle. The AA1100-O flier sheets ranged in thickness from 0.127 to 1.016 mm. The velocity of the fliers was directly measured by in situ photon Doppler velocimetry (PDV) and kept nearly constant at 670 m/s. The collision angles were controlled by a customized steel target with a set of various collision angles ranging from 8 deg to 28 deg. A numerical solid mechanics model was optimized for mesh sizes and provided to confirm the wavelength variation. Temperature estimates from the model were also performed to predict local melting and its complex spatial distribution near the weld interface and to compare that prediction to experiments.

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Fig. 3

(a) Welds made by aluminum fliers of varied thicknesses and (b) cross section drawing of a grooved target showing the set collision angles and PDV hole in the middle

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Fig. 1

A schematic of the vaporizing foil actuator welding process coupled with in situ photon Doppler velocimetry

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Fig. 4

A model depicting the impact welding process with the mesh size optimized for simulation

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Fig. 2

The geometry of the vaporizing foil actuator used in this study

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Fig. 5

Comparison of interface morphology varied by the prefixed collision angles of a grooved target for the 1.016 mm thick flier

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Fig. 8

Comparison of interface morphology varied by the flier thickness at a collision angle of 16 deg. Temperatures are indicated in the contour plots.

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Fig. 9

(a) Experimental data showing variations in interfacial wavelength depending on flier thickness and prefixed collision angle between AA1100-O flier and AISI 1018 steel target. The impact velocity was kept constant at 670 m/s for all angles and flier thicknesses. Numerical results and experimental results are compared for (b) collision angle α variation with a 1.016 mm thick flier and (c) flier thickness t variation with a 16 deg collision angle.

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Fig. 7

Velocity traces for 0.127, 0.254, 0.508, and 1.016 mm thick AA1100-O fliers with respect to traveled distance. The vertical and horizontal dotted lines signify the standoff distance and the targeted impact velocity, respectively.

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Fig. 10

Weld interface made with a 1.016 mm thick AA1100-O flier at a 20 deg collision angle. The wavelength measurement from the center of the slope is used for the wavelength comparison.

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Fig. 6

(a) Weld interface made with a 1.016mm thick AA1100-O flyer at a 20 deg collision angle (b) intermixed zone (c) energy dispersive spectroscopy map and (d) line scan results showing compositions across the intermixed zone



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