Papers by Keyword: Pressure Welding

Abstract: It is shown that formation of ultrafine-grained structure in EK61 superalloy up to grain sizes less than 1 μm provides to realize superplastic properties. The influence of deformation in the temperature range 600-1100 °C and strain rate range 10^-4s^-1– 10^-3s^-1 on the microstructure and properties of ultrafine-grained nickel-based alloy EK61 is studied. It is established that in temperature range 750-900 °C the alloy demonstrates superplasticity (SP) characteristics: strain rate sensitivity factor “m” correspond to 0.39-0.59, stable structure and low changes in the form and size of grains. The maximum SP is displayed at temperatures of 800 °C, wherein the elongation is 1431 %. It has been experimentally confirmed that the use of low-temperature superplasticity is a promising for processing sound solid phase joints by pressure welding of similar and dissimilar Ni-based superalloys.

Abstract: Joining of steel and aluminum is a commonly applied manufacturing process to obtain lightweight components. Cold pressure welding by means of direct extrusion allows gaining high bond strengths between these two materials. The contacting surfaces are usually prepared by using scratch brushing to enhance the bond strength. Most studies have shown the benefit of the brushing whereas the resulting bond strength scatters. Variations in the parameters of the brush treatment are presumed to be a major cause for the variations in strength. Within the presented work, scratch brushing parameters are adjusted to further improve the resulting bond strength. Cracking of the surfaces at low strains is a beneficial effect to enhance the bond strength. Therefore, the crack formation of the surfaces brushed under different conditions is analyzed in tensile tests. Roughness, residual stresses and microstructural changes of the aluminum surfaces resulting from brushing processes are evaluated to enhance the understanding of the cracking mechanism. Concluding, the brushing parameters are adjusted to improve bond strengths up to the material strength of the used aluminum.

Abstract: The paper presents the results of finite element analysis of plastic deformation in the contact zone of dissimilar superalloys subjected to pressure welding. The results are compared for the two cases: with and without relief on the surfaces of parts to be welded. It is shown that the relief made on the surface can either decrease or increase the area of deformation stagnant zones, depending on the relief shape. The results of simulations are compared with the experimental test results.

Abstract: Application of the conventional superplasticity (SP) allows producing the unique hollow structures. One remarkable example is the hollow titanium blade of the air engine fan produced by Rolls-Royce. However, high temperature titanium alloys processing (~ 927 °С) limits wide industrial application of the conventional SP. The solution of the mentioned issue can be found through the application of low-temperature SP. Ti-6Al-4V alloy with ultrafine grain structure at the temperature range of 600 ­ 800 °С has enough ductility resources for the superplastic forming (SPF) of the parts with the complicated shape. The formation of pores in Ti-6Al-4V alloy at uniaxial and biaxial tension at the temperature 600 °С is not observed. The effect of low-temperature SP also allows lowering pressure welding (PW) temperature essentially. Herewith, there is a possibility to produce the hollow parts by the combination of SPF and PW. The main goal is the optimization of the technological scheme and processing temperature. The use of the low-temperature SP provides high quality of hollow components such as blades.

Abstract: In this study the typical bonding faults of three layer-plated aluminum sheets are investigated. The bonding was performed between AlMn1Si0.8 and AlSi10 alloys using hot rolling (a VON ROLL experimental duo mill). The experimental temperatures were 460, 480 and 500 °C. T-peel test provided a good description about the quality of bonding. Structure analysis was also performed by light microscopy to detect typical bonding faults. The aim of this investigation is to produce some typical bonding faults and find the cause of formation. The influence of the rolling temperature and surface roughness on the bonding was also analyzed. Rolling schedule and the role of first pass on the development of perfect bonding were experimentally determined.

Abstract: This paper provides details about the adjacent parallel seam welding of a pair of aluminum sheets by a magnetic pulse welding (MPW) method. An impulse discharge current from a capacitor bank passes through a flat one-turn coil and concentrates on two parallel along the narrow middle parts of the coil. A magnetic flux is suddenly generated around the middle parts. This flux intersects the sheets which are overlapped on the middle parts. The resulting eddy currents are induced in the sheets, applying two parallel strong electromagnetic forces to them. The sheets having a gap collide with each other at high speed in two parallel. In this time, four metal jets occur just ahead of the collision front along the middle parts. Two metal jets occurring in the inside collide with each other if the experimental conditions are suitable.

Abstract: The paper describes the results of long-term investigations on the development of the technology of superplastic forming and pressure welding (SPF/PW) conducted at the Institute for Metals Superplasticity Problems, Russian Academy of Sciences for producing standard articles of aero-space engineering, such as hollow blades, wing and shell panels. The process of solid state joint formation in titanium alloy sheets during SPF was studied. Different investigation techniques were developed. The results of the mechanical and fatigue testing as well as non-destructive inspection of hollow blades are presented. The prospects of the development of the SPF/PW technology are considered and the latest results are discussed.

Abstract: In this study the aluminium sheet bonding properties is investigated. The bonding was performed between 1050 and 3003 Al alloys using mechanical press (eccentric press) or hot rolling (VON ROLL experimental duo mill). The experimental temperatures were 400, 450, 500°C. The goodness of bonding was tested by tensile test and T-peel test. The optimal parameters were developed for the T-peel test. The results obtained from these tests give a good description about the quality of bonding. Structure analysis was also performed by LM and SEM to detect the typical bonding faults.

Abstract: In extrusion of hollow Al-profiles two kinds of pressure welds are present inside the extrusion. One is called the charge weld (CW) and forms across the boundary interface between two billets extruded in sequence. The other is the seam weld (SW) which extends longitudinally along the extruded profile and the extrusion metal behind each die bridge. It is considered to form because of the splitting of the extrusion metal over the die bridge into metal streams which flow past the bridge and rejoin as they encounter behind the bridge. Over the time attempts have been made to explain the mechanics of extrusion welding for both the CW and the SW. Still there is lack of understanding of how these welds form, the main reasons for this is that the deformation conditions around a die bridge are complex and difficult to investigate. Because of the recent advancement of two technological fields, experimental grid pattern analysis and simulation of metal flow by FEA; new tools for analysis of the mechanics of formation of the SW and the CW are now available. The simplest possible case of 2D-extrusion seam welding is considered here and an attempt is made to describe the fundamental deformation mechanisms present when this weld forms behind a butt-ended die bridge.

Abstract: Braze Pressure Welding (BPW) with high frequency induction heating is a newly developed pressure welding technique using interlayer metals for welding the general steel pipes for pipe arrangement in buildings. BPW enables to make joints by solid-state welding in air using a flux sheet which is also developed for this technique. In this method, the interlayer metal is expected to play the primary role in making high performance joints. At a joining temperature, the melted interlayer removes contaminations from the joining surfaces of the base metals. Then the liquid filler is discharged from the joining interface by the joining pressure, and forms fillets at the gaps around the joint. In this stage, the joining pressure is relatively small, so the welding deformation can be restrained to a minimum. The fillets have the effects both on relaxing the stress concentration at the joint and on increasing the joining area, which contribute to the strengthening of the joint. Thus, the high quality pipe joining without the dispersion in joint properties due to welder’s skill can be performed. In this report, the concept and merits of BPW are explained, and the results of the investigation on the cleaning effect of the interlayer metal and the effects of fillet formation on strengthening the joint are discussed. The practical application of BPW in Japan is also introduced.