Dissimilar metals welding processes realized by vaporizing metal foils

IF 4.2 2区 工程技术 Q2 ENGINEERING, MANUFACTURING Advances in Manufacturing Pub Date : 2024-07-12 DOI:10.1007/s40436-024-00506-z
Sheng Cai, Zhi-Chao Deng, Jia-Nan Wang, Nan Zhang
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Abstract

In high-velocity impact welding (HVIW), vaporizing foil actuator welding (VFAW) can be utilized to join dissimilar metals. In comparison with conventional welding processes, the VFAW process minimizes energy loss, enhances weld strength, and effectively mitigates issues of overheating or material deformation associated with traditional welding methods. In this study, VFAW was utilized to successfully weld three different metal materials (Cu, Al6061-T6, Q235). An accurate smoothed particle hydrodynamics (SPH) model was established based on the experimental results. The impacts of collision angle and velocity of the flyer on the interface morphology of Cu/Al6061-T6 weld were investigated using the SPH method. The experimental results show that with an increase in the collision angle from 0° to 20°, both the wavelength and amplitude of the welding interface significantly increase. The tail vortex phenomenon also becomes more pronounced with the angle of tail rotation caused by particle motion gradually increasing. But when the collision angle exceeds 20°, the wavelength and amplitude of the welding interface tend to stabilize while its influence on tail vortex phenomenon decreases. The tail rotation angle induced by particle motion continues to increase, although at a decreasing rate. When the initial collision angle is kept constant, both the wavelength and amplitude of the welding interface continue to rise with increasing collision velocity up to 900 m/s. The wake vortex phenomenon becomes more pronounced as the number of particles in the jet gradually increases.

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通过蒸发金属箔实现的异种金属焊接工艺
在高速冲击焊接(HVIW)中,蒸发箔激励器焊接(VFAW)可用于连接异种金属。与传统焊接工艺相比,VFAW 工艺最大限度地减少了能量损失,提高了焊接强度,并有效缓解了与传统焊接方法相关的过热或材料变形问题。本研究利用 VFAW 成功焊接了三种不同的金属材料(铜、Al6061-T6 和 Q235)。根据实验结果建立了精确的平滑粒子流体力学(SPH)模型。利用 SPH 方法研究了飞鸟的碰撞角度和速度对铜/Al6061-T6 焊缝界面形态的影响。实验结果表明,随着碰撞角从 0°增大到 20°,焊接界面的波长和振幅都明显增大。随着粒子运动引起的尾部旋转角度逐渐增大,尾涡现象也变得更加明显。但当碰撞角超过 20°时,焊接界面的波长和振幅趋于稳定,而其对尾涡现象的影响则减弱。粒子运动引起的尾部旋转角继续增大,但增大的速度在减小。当初始碰撞角保持不变时,焊接界面的波长和振幅都随着碰撞速度的增加而持续上升,最高可达 900 m/s。随着射流中粒子数量的逐渐增加,尾流漩涡现象变得更加明显。
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来源期刊
Advances in Manufacturing
Advances in Manufacturing Materials Science-Polymers and Plastics
CiteScore
9.10
自引率
3.80%
发文量
274
期刊介绍: As an innovative, fundamental and scientific journal, Advances in Manufacturing aims to describe the latest regional and global research results and forefront developments in advanced manufacturing field. As such, it serves as an international platform for academic exchange between experts, scholars and researchers in this field. All articles in Advances in Manufacturing are peer reviewed. Respected scholars from the fields of advanced manufacturing fields will be invited to write some comments. We also encourage and give priority to research papers that have made major breakthroughs or innovations in the fundamental theory. The targeted fields include: manufacturing automation, mechatronics and robotics, precision manufacturing and control, micro-nano-manufacturing, green manufacturing, design in manufacturing, metallic and nonmetallic materials in manufacturing, metallurgical process, etc. The forms of articles include (but not limited to): academic articles, research reports, and general reviews.
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