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Title: Pulsed Joining Of Body-In-White Components

The objective of this project was to develop cost efficient high quality pulsed welding (PW) technology for joining 6xxx Aluminum and High Strength Steel (with tensile strength above 580MPa) components enabling broad usage of hydroformed parts and leading to substantial weight reduction of cars and trucks to reduce US demand on petroleum, lower carbon emissions and energy expenditures. In general, pulsed welding is a form of impact welding where two dissimilar metal pieces are joined by accelerating one to velocities exceeding 300m/s at which point the first piece strikes the second and forms a weld. In this work, two methods were used to accelerate the flyer material: Electro-Magnetic (EM) pulse and Electro-Hydraulic (EH) pulse launching. The advantage of pulsed welding techniques is that welds can be formed between two materials that cannot otherwise be welded: high strength aluminum and high strength steel. The technical objectives of the project included: 1) developing cost affordable production feasible tooling design for PW of 6xxx aluminum to High Strength steel with strengths above 580MPa; 2) demonstrating that fabricated joints can exceed the required service load strength initially at the coupon level and then at the component level; 3) developing fundamental understanding of the mechanismsmore » of joint formation and conditions leading to formation of high quality PW joint; and 4) creating a numerical model predicting the tooling and electric discharge parameters necessary for the joint formation and that satisfy the targeted strength parameters. The project successfully developed: 1) EM and EH pulsed welds between high strength aluminum with tensile strengths exceeding 240MPa and steels exceeding 580MPa; 2) pulsed welds of extrusions with strengths exceeding project requirements; 3) EM and EH flyer launch models and 4) weld interface formation models. However, the grant holder, Ford Motor Company, could see no path to commercialization and the work was discontinued at the end of the first budget period.« less
  1. Ford Motor Company, Dearborn, MI (United States)
Publication Date:
OSTI Identifier:
DOE Contract Number:
Resource Type:
Technical Report
Research Org:
Ford Motor Company, Dearborn, MI (United States)
Sponsoring Org:
Country of Publication:
United States