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Title: Joining sheet aluminum AA6061-T4 to cast magnesium AM60B by vaporizing foil actuator welding: Input energy, interface, and strength

Abstract

Dissimilar joining of sheet aluminum AA6061-T4 to cast magnesium AM60B was achieved by vaporizing foil actuator welding (VFAW). Three input energy levels were used (6, 8, and 10 kJ), and as a trend, higher input energies resulted in progressively higher flyer velocities, more pronounced interfacial wavy features, larger weld zones, higher peel strengths, and higher peel energies. In all cases, weld cross section revealed a soundly bonded interface characterized by well-developed wavy features and lack of voids and continuous layers of intermetallic compounds (IMCs). At 10 kJ input energy, flyer speed of 820 m/s, peel strength of 22.4 N/mm, and peel energy of 5.2 J were obtained. In lap-shear, failure occurred in AA6061- T4 flyer at 97% of the base material’s peak tensile load. Peel samples failed along the weld interface, and the AM60B-side of the fracture surface showed thin, evenly-spaced lines of Al residuals which had been torn out of the base AA6061-T4 in a ductile fashion and transferred over to the AM60B side, indicating very strong AA6061-T4/AM60B bond in these areas. Furthermore, this work demonstrates VFAW’s capability in joining dissimilar lightweight metals such as Al/Mg, which is expected to be a great enabler in the ongoing push formore » vehicle weight reduction.« less

Authors:
ORCiD logo [1];  [1];  [1]
  1. The Ohio State Univ., Columbus, OH (United States)
Publication Date:
Research Org.:
The Ohio State Univ., Columbus, OH (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE), Vehicle Technologies Office (EE-3V)
Contributing Org.:
The Ohio State University
OSTI Identifier:
1408920
Grant/Contract Number:  
EE0006451
Resource Type:
Accepted Manuscript
Journal Name:
Journal of Manufacturing Processes
Additional Journal Information:
Journal Volume: 30; Journal Issue: C; Journal ID: ISSN 1526-6125
Publisher:
Society of Manufacturing Engineers; Elsevier
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; Impact welding; Vaporizing foil actuator welding; Dissimilar metal joining; Sheet aluminum; Cast magnesium

Citation Formats

Liu, Bert, Vivek, Anupam, and Daehn, Glenn S. Joining sheet aluminum AA6061-T4 to cast magnesium AM60B by vaporizing foil actuator welding: Input energy, interface, and strength. United States: N. p., 2017. Web. doi:10.1016/j.jmapro.2017.09.008.
Liu, Bert, Vivek, Anupam, & Daehn, Glenn S. Joining sheet aluminum AA6061-T4 to cast magnesium AM60B by vaporizing foil actuator welding: Input energy, interface, and strength. United States. https://doi.org/10.1016/j.jmapro.2017.09.008
Liu, Bert, Vivek, Anupam, and Daehn, Glenn S. Tue . "Joining sheet aluminum AA6061-T4 to cast magnesium AM60B by vaporizing foil actuator welding: Input energy, interface, and strength". United States. https://doi.org/10.1016/j.jmapro.2017.09.008. https://www.osti.gov/servlets/purl/1408920.
@article{osti_1408920,
title = {Joining sheet aluminum AA6061-T4 to cast magnesium AM60B by vaporizing foil actuator welding: Input energy, interface, and strength},
author = {Liu, Bert and Vivek, Anupam and Daehn, Glenn S.},
abstractNote = {Dissimilar joining of sheet aluminum AA6061-T4 to cast magnesium AM60B was achieved by vaporizing foil actuator welding (VFAW). Three input energy levels were used (6, 8, and 10 kJ), and as a trend, higher input energies resulted in progressively higher flyer velocities, more pronounced interfacial wavy features, larger weld zones, higher peel strengths, and higher peel energies. In all cases, weld cross section revealed a soundly bonded interface characterized by well-developed wavy features and lack of voids and continuous layers of intermetallic compounds (IMCs). At 10 kJ input energy, flyer speed of 820 m/s, peel strength of 22.4 N/mm, and peel energy of 5.2 J were obtained. In lap-shear, failure occurred in AA6061- T4 flyer at 97% of the base material’s peak tensile load. Peel samples failed along the weld interface, and the AM60B-side of the fracture surface showed thin, evenly-spaced lines of Al residuals which had been torn out of the base AA6061-T4 in a ductile fashion and transferred over to the AM60B side, indicating very strong AA6061-T4/AM60B bond in these areas. Furthermore, this work demonstrates VFAW’s capability in joining dissimilar lightweight metals such as Al/Mg, which is expected to be a great enabler in the ongoing push for vehicle weight reduction.},
doi = {10.1016/j.jmapro.2017.09.008},
journal = {Journal of Manufacturing Processes},
number = C,
volume = 30,
place = {United States},
year = {2017},
month = {9}
}

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Works referencing / citing this record:

Joining Performance and Microstructure of the 2024/7075 Aluminium Alloys Welded Joints by Vaporizing Foil Actuator Welding
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Fracture Characteristics and Analysis in Dissimilar Cu-Al Alloy Joints Formed via Electromagnetic Pulse Welding
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High-Velocity Impact Welding Process: A Review
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Joining Aluminium Alloy 5A06 to Stainless Steel 321 by Vaporizing Foil Actuators Welding with an Interlayer
journal, January 2019