Papers by Keyword: Ultrasound Support

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Authors: Benjamin Strass, Guntram Wagner, Dietmar Eifler
Abstract: To realize modern light weight constructions it is more and more necessary to combine the advantages of dissimilar materials. Fusion welding of dissimilar metals is in the most cases difficult or even impossible as a result of different melting points of the materials and the development of undesirable brittle intermetallic phases in the welding zone. This often leads to joint strengths considerable below the tensile strength of the base materials. By using Friction Stir Welding (FSW) as a pressure welding method, it is possible to reduce the development of the intermetallic phases of Al/Mg-joints significantly. But as calculated phase diagrams and high resolution microscopic SEM-investigations have shown it is not feasible to avoid them completely. The intermetallic phases form in the contact area very small continuous layers between the joining partners. On the other side it is known that ultrasonic energy can crack oxide layers. Hence a hybrid welding system at the Institute of Materials Science and Engineering (WKK) at the University of Kaiserslautern was developed called “Ultrasound Supported Friction Stir Welding (US-FSW)” with the aim to shatter the brittle interlayer lines and to scatter fragments in the welding area during the FSW process. Pre-investigations have shown that for US-FSW-joints between Al wrought alloys and Mg cast alloys the strength can be increased up to 30% in comparison to conventional friction stir welds. Currently, further investigations are carried out with joints between AC-48000 and AZ80.
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Authors: Benjamin Strass, Guntram Wagner, Christian Conrad, Bernd Wolter, Sigrid Benfer, Wolfram Fürbeth
Abstract: Fusion welding of dissimilar metals is in the most cases difficult or even impossible as a result of different melting points and the development of undesirable brittle intermetallic phases. This often leads to joint strengths considerable below the tensile strength of the base materials. By using Friction Stir Welding (FSW) it is possible to reduce the development of the intermetallic phases of Al/Mg-joints significantly but not to avoid them completely. Hence a hybrid welding system at the WKK of the University of Kaiserslautern was developed called “Ultrasound Supported Friction Stir Welding (US-FSW)” with the aim to shatter the brittle interlayer lines and to scatter fragments in the welding area during the FSW process. Pre-investigations have shown that for Al/Mg-US-FSW-joints the strength can be increased up to 30% in comparison to conventional FSW. Moreover for the reliable detection of nonconformities in the weld during a post-process inspection by suitable non-destructive testing (NDT) methods is necessary. Also there is a strong need for better process monitoring and control by in-process NDT methods. Furthermore the corrosion behavior of the basic materials and hybrid-joints was investigated by electrochemical methods indicating an increased corrosion of the Mg alloy in the area of the Al/Mg-butt weld.
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