Shock effects on the upper limit of the collision weld process window

doi:10.1007/s40436-023-00472-y

Advances in Manufacturing ›› 2024, Vol. 12 ›› Issue (2): 365-378.doi: 10.1007/s40436-023-00472-y

• • 上一篇

Shock effects on the upper limit of the collision weld process window

Blake Barnett^1,2, Anupam Vivek¹, Glenn Daehn¹

1 Department of Materials Science and Engineering, The Ohio State University, Columbus, OH 43210, USA;
2 Army Research Directorate, Army Research Laboratory, DEVCOM, Aberdeen Proving Ground, Harford, MD 21005, USA

收稿日期:2023-04-21 修回日期:2023-06-14 发布日期:2024-05-16
通讯作者: Blake Barnett,E-mail:barnett.615@buckeyemail.osu.edu E-mail:barnett.615@buckeyemail.osu.edu
作者简介:Blake Barnett is a doctoral candidate at The Ohio State University in welding engineering. He earned his B.S. in materials science and engineering from Johns Hopkins University in 2012, followed by employment at the DEVCOM Army Research Laboratory (ARL) at the ARL Center for Cold Spray with a focus on coatings process optimization and application development. He began his graduate studies at OSU 2018 as an awardee of the Department of Defense SMART Scholarship for Service Program. His graduate work focuses on solid-state joining and manufacturing process optimization to develop applications for metals with highly architected, thermally sensitive microstructures;
Anupam Vivek is a research scientist at The Ohio State University (OSU) in the Impulse Manufacturing Laboratory led by Dr. Glenn S. Daehn. He earned a Ph.D. from OSU in 2012 in Materials Science and Engineering, and a B.S. from IIT Kharagpur in 2007. His research focuses on high-velocity and high-strain-rate metal working. specializes in developing and experimentally validating analytical and numerical models for collision-weld optimization;
Glenn Daehn is the Mars G. Fontana Professor of Metallurgical Engineering at The Ohio State University where he has been a Professor since 1988. He earned a Ph.D. from Stanford University and B.S. from Northwestern University in materials science and engineering. Professor Daehn's research is focused on novel materials processing with a particular focus on plastic deformation and impulse-based processes. Daehn has also been instrumental in founding several technical outreach organizations including the Ohio Manufacturing Institute, the LIFT Manufacturing USA Institute, Ohio State's Center for Design and Manufacturing Excellence, International Impulse Forming Group and the National Science Foundation HAMMER Engineering Research Center.

Shock effects on the upper limit of the collision weld process window

Blake Barnett^1,2, Anupam Vivek¹, Glenn Daehn¹

1 Department of Materials Science and Engineering, The Ohio State University, Columbus, OH 43210, USA;
2 Army Research Directorate, Army Research Laboratory, DEVCOM, Aberdeen Proving Ground, Harford, MD 21005, USA

Received:2023-04-21 Revised:2023-06-14 Published:2024-05-16
Contact: Blake Barnett,E-mail:barnett.615@buckeyemail.osu.edu E-mail:barnett.615@buckeyemail.osu.edu

摘要/Abstract

摘要： The maximum flyer impact velocity based on a dynamic solidification cracking mechanism is proposed to describe the upper limit of collision welding process windows. Thus, the upper limit of the weld window is governed by the evolution of dynamic stresses and temperatures at the weld interface. Current formulations for the upper limit of the collision weld window assume that both the flyer and target are made of the same material and approximate stress propagation velocities using the acoustic velocity or the shear wave velocity of the weld material. However, collision welding fundamentally depends on the impacts that generate shockwaves in weld members, which can dominate the stress propagation velocities in thin weld sections. Therefore, this study proposes an alternative weld window upper limit that approximates stress propagation using shock velocities calculated from modified 1-D Rankine-Hugoniot relations. The shock upper limit is validated against the experimental and simulation data in the collision welding literature, and offers a design tool to rapidly predict more accurate optimal collision weld process limits for similar and dissimilar weld couples compared to existing models without the cost or complexity of high-fidelity simulations.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00472-y

关键词: Collision welding, Solid-state welding, Shock impact, Weld process modelling, Explosive bonding, Laser impulse welding (LIW)

Abstract: The maximum flyer impact velocity based on a dynamic solidification cracking mechanism is proposed to describe the upper limit of collision welding process windows. Thus, the upper limit of the weld window is governed by the evolution of dynamic stresses and temperatures at the weld interface. Current formulations for the upper limit of the collision weld window assume that both the flyer and target are made of the same material and approximate stress propagation velocities using the acoustic velocity or the shear wave velocity of the weld material. However, collision welding fundamentally depends on the impacts that generate shockwaves in weld members, which can dominate the stress propagation velocities in thin weld sections. Therefore, this study proposes an alternative weld window upper limit that approximates stress propagation using shock velocities calculated from modified 1-D Rankine-Hugoniot relations. The shock upper limit is validated against the experimental and simulation data in the collision welding literature, and offers a design tool to rapidly predict more accurate optimal collision weld process limits for similar and dissimilar weld couples compared to existing models without the cost or complexity of high-fidelity simulations.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-023-00472-y

Key words: Collision welding, Solid-state welding, Shock impact, Weld process modelling, Explosive bonding, Laser impulse welding (LIW)

Blake Barnett, Anupam Vivek, Glenn Daehn. Shock effects on the upper limit of the collision weld process window[J]. Advances in Manufacturing, 2024, 12(2): 365-378.

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Shock effects on the upper limit of the collision weld process window

Shock effects on the upper limit of the collision weld process window

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