Enhancement of the interface of friction welded steel-aluminium joints

authored by: Bernd-Arno Behrens, Deniz Duran, Tim Matthias, Ingo Ross
Abstract: Lightweight multi-material components are of great importance for the transport industry. Not only the component’s weight can be decreased, but also its local properties can be adapted to different loading profiles. Tailored Forming is a novel concept for producing multi-material components. By using a joining process, the creation of a bond between different materials takes place in the first step of the process chain. In the subsequent steps, multi-material workpieces are processed in their joined state while maintaining or improving the joint strength. This study focuses on steel-aluminium joints, which were created by friction welding and further processed by induction heating and impact extrusion. A counter pressure superposition mechanism was implemented in the extrusion tooling to control the stress state during plastic deformation. Flow behaviours of steel and aluminium are largely different at a given temperature, which necessitates a near step-function temperature distribution in the hybrid billet to obtain matching flow stresses. An inductive heating strategy was developed which led to a temperature gradient in the billets before extrusion. Extruded billets were analysed by destructive testing methods and metallography. The bond could be maintained after extrusion when counter pressure superposition was used; but no improvement could be obtained. Without counter force superposition, however, cracks were observed in the joining interface and the joint strength decreased. This paper discusses the aforementioned findings in the current process design and makes suggestions on how the involved processes should be reconfigured to improve the joint strength.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
Type: Article
Journal: Production Engineering
Volume: 15
Pages: 169-176
No. of pages: 8
ISSN: 0944-6524
Publication date: 04.2021
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Mechanical Engineering, Industrial and Manufacturing Engineering
Electronic version(s): https://doi.org/10.1007/s11740-020-00994-5 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{9306e37f064e4f2292eb91228a970273,
title = "Enhancement of the interface of friction welded steel-aluminium joints",
abstract = "Lightweight multi-material components are of great importance for the transport industry. Not only the component{\textquoteright}s weight can be decreased, but also its local properties can be adapted to different loading profiles. Tailored Forming is a novel concept for producing multi-material components. By using a joining process, the creation of a bond between different materials takes place in the first step of the process chain. In the subsequent steps, multi-material workpieces are processed in their joined state while maintaining or improving the joint strength. This study focuses on steel-aluminium joints, which were created by friction welding and further processed by induction heating and impact extrusion. A counter pressure superposition mechanism was implemented in the extrusion tooling to control the stress state during plastic deformation. Flow behaviours of steel and aluminium are largely different at a given temperature, which necessitates a near step-function temperature distribution in the hybrid billet to obtain matching flow stresses. An inductive heating strategy was developed which led to a temperature gradient in the billets before extrusion. Extruded billets were analysed by destructive testing methods and metallography. The bond could be maintained after extrusion when counter pressure superposition was used; but no improvement could be obtained. Without counter force superposition, however, cracks were observed in the joining interface and the joint strength decreased. This paper discusses the aforementioned findings in the current process design and makes suggestions on how the involved processes should be reconfigured to improve the joint strength.",
keywords = "Friction Welding, Impact Extrusion, Multi-Material Components, Tailored Forming",
author = "Bernd-Arno Behrens and Deniz Duran and Tim Matthias and Ingo Ross",
note = "Funding Information: Open Access funding enabled and organized by Projekt DEAL. Funded by the Deutsche Forschungsgemeinschaft (DFG, German Research Foundation)—CRC 1153, subproject B03 and T02–252662854. The authors thank the German Research Foundation (DFG) for their financial support of this project. Publisher ",
year = "2021",
month = apr,
doi = "10.1007/s11740-020-00994-5",
language = "English",
volume = "15",
pages = "169--176",
journal = "Production Engineering",
issn = "0944-6524",
publisher = "Springer Verlag",
number = "2",
}