Thin Conductors: a New Tool for Collision Welding 05/07/2013, I2FG - - PowerPoint PPT Presentation

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Thin Conductors: a New Tool for Collision Welding 05/07/2013, I2FG - - PowerPoint PPT Presentation

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Electrically Driven Vaporization of Thin Conductors: a New Tool for Collision Welding 05/07/2013, I2FG Technical Workshop Anupam Vivek Post-Doctoral Researcher: Daehn Research Group I2FG Plenary Meeting, Anupam Vivek, 1 vivek.4@osu.edu

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I2FG Plenary Meeting, Anupam Vivek, vivek.4@osu.edu 1

05/07/2013, I2FG Technical Workshop Anupam Vivek Post-Doctoral Researcher: Daehn Research Group

Electrically Driven Vaporization of Thin Conductors: a New Tool for Collision Welding

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I2FG Plenary Meeting, Anupam Vivek, vivek.4@osu.edu 2

Outline

  • Collision welding introduction
  • Vaporizing Foil Welding
  • Challenges and future work
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Collision Welding Introduction

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I2FG Plenary Meeting, Anupam Vivek, vivek.4@osu.edu 4

  • Solid state welds with reduced intermetallic formation (Hishashi

et al, 2009; Kore et al, 2009) or very localized melting at the

interface in some cases (Aizawa et al, 2004; Gobel et al, 2010, Zhang

et al, 2010). Welded region stronger than parent material, due

to grain refinement and hardness increase (Zhang et al, 2010), various theories for the mechanism for impact welding

(Shribman et al, 2006; Brown, 1978), Dissimilar metal welding

possible

4 (Picture courtesy: PhD Thesis, Yuan Zhang, 2010)

Salient features

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Explosion Welding (EXW)

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Products

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I2FG Plenary Meeting, Anupam Vivek, vivek.4@osu.edu 7

Issues with Explosives

  • Difficulty in handling
  • Increasingly stringent regulations
  • Specific training needed
  • Needs big spaces for safe operation
  • Critical volume: minimum physical size, a charge of a

specific explosive should have to sustain its own detonation wave

  • Mostly for large scale operations
  • Tools must be very tough. Their life has been

unpredictable

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Magnetic Pulse Welding (MPW)

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I2FG Plenary Meeting, Anupam Vivek, vivek.4@osu.edu 13

Issues with Magnetic Pulse Technology

  • Longevity of electromagnetic actuators at high pressure, temperature and

cycle time

  • Frequent inspection for cracks and voids needed to insure efficiency of the

actuators

  • Fabrication of coils is generally an expensive process
  • Requires an electrically conductive flyer material (unless a ‘driver’ is used)

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Pictures courtesy: Golovashchenko, SF., 2007, Material formability and coil design in electromagnetic forming, Journal of materials science and performance, Volume: 16 Issue: 3 Pages: 314- 320 DOI: 10.1007/s11665-007-9058 7, Published: June 2007

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I2FG Plenary Meeting, Anupam Vivek, vivek.4@osu.edu 14

Vaporizing Foil Welding (VFW): Technique

  • What happens when a high current is passed

through a thin conductor?

wire/foil Capacitor Circuit Inductance Switch Circuit Resistance Voltage W- C- L- S- R- V- Basic circuit for rapid metal vaporization

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I2FG Plenary Meeting, Anupam Vivek, vivek.4@osu.edu 15

What happens?

  • When energy deposition rate is very high then a thin

conductor can be heated much above its sublimation energy due to inertial and magnetic forces

  • When these inertial forces let go, this stored energy

converts to kinetic energy of the vaporized metal and releases as a pressure pulse

15 (Sedoi et al, 1999)

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Data and analysis

Time (µs)

Current (kAmps) Voltage (Volts)

Burst Excess energy= E(t) – Hb (0.5 kJ per 0.0254 mm of thickness)

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  • A. Vivek, G.A. Taber, J.R. Johnson, S.T. Woodward,

Glenn S. Daehn, Electrically driven plasma via vaporization of metallic conductors: A tool for impulse metal working, Journal of Materials Processing Technology, Volume 213, Issue 8, August 2013, Pages 1311-1326, ISSN 0924-0136, 10.1016/j.jmatprotec.2013.02.010.

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Welding: procedure

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Vaporizing Foil Driven Welding

  • No welding in the area just above the

former position of foil-zero impact angle

  • Peel test needs yields a varied spectrum of

strength values

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Interface morphology and peel strength

5 10 15 20 25

Cu 110, CP Ti Cu 110, 1018 Steel Cu 110, Al 6061 CP Ti, 1018 Steel Mg AZ31B, Al 6061

Peel Strength (Nt/mm)

CP Ti Cu 110 100 μm Cu 110 1018 Steel 100 μm Cu 110 Al 6061 50 μm CP Ti 1018 Steel 50 μm Mg AZ31B Al 6061 50 μm

Foil actuator: Aluminum, 0.003” thick, Electrical energy: 7.2 kJ

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Material exchange

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Lap shear test

13.4 15.5 35.0 Sustained shear strength (MPa)

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Interlayer for creating stronger interfaces

  • Nickel interlayer:

compatible with both sides and acts as a diffusion barrier

  • Single shot with 7.2

kJ input energy

  • Much higher peel

strength value

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Photonic Doppler Velocimetry

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Groovy Experiment: welding window

estimation

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20°

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Groovy Experiment

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VFW: Summary

  • Developed at OSU. A variation of explosion welding - in safe laboratory
  • environment. Unlike MPW, does not require an electrically conductive

flyer material

  • Dissimilar materials welded with varying strength and interface structure
  • Strong welds associated with wavy interfaces free of intermetallics

whereas weaker welds were riddled with defects

  • Peel test is more discriminating in terms of strength of the welds
  • Velocities upto 560 m/s observed using PDV
  • Can be used for quick determination of welding windows for any weldable

couple

  • Welds created over lengths of upto 50 mm
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I2FG Plenary Meeting, Anupam Vivek, vivek.4@osu.edu 29

  • A. Vivek, G.A. Taber, J.R. Johnson, S.T. Woodward,

Glenn S. Daehn, Electrically driven plasma via vaporization of metallic conductors: A tool for impulse metal working, Journal of Materials Processing Technology, Volume 213, Issue 8, August 2013, Pages 1311-1326, ISSN 0924-0136, 10.1016/j.jmatprotec.2013.02.010.

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I2FG Plenary Meeting, Anupam Vivek, vivek.4@osu.edu 39

Challenges and future work

  • Simulation work: ideal gas assumption
  • Foil shape effects
  • Options for insulation material
  • Die-less forming
  • Industrial adaptation
  • Development of standardized peel testing for

metal-to-metal welds

  • ?