Feasibility and Mechanistic Analysis of 3-Stack Aluminium-Steel Spot Joints Using Vaporizing Foil Actuator Welding with Partial Pre-Forming
Loading...
Files
Date
2025-08-26
Journal Title
Journal ISSN
Volume Title
Publisher
Alternative Title(s)
Abstract
The advancement of spot joining techniques is crucial for automotive manufacturing, yet
integrating aluminum-steel (Al-Fe), combinations presents inherent challenges. Traditional
methods, such as resistance spot welding (RSW), often lead to the formation of brittle
intermetallic compounds (IMCs) and residual stresses, compromising joint integrity.
Innovative strategies that enhance mechanical performance while optimizing weight are
essential for multi-material assemblies. Advanced techniques like vaporizing foil actuator
welding (VFAW) offer a promising solution, enabling metallurgical bonding with minimal
heat-induced damage, thereby reducing residual stresses and improving structural relia bility.
This study investigates the feasibility of fabricating a 3-stack (Al-Fe-Fe) spot joint
using VFAW, employing partial pre-forming of intermediate plates to achieve single-step
joining. Smoothed particle hydrodynamics (SPH) modeling is applied to analyze transient
stress wave propagation and interfacial jetting dynamics, elucidating their mechanistic
influence on interfacial bond formation during high-speed multi-plate interactions. The
findings underscore the critical role of partial pre-forming in enabling successful 3-stack
VFAW joints.
Description
Table of contents
Keywords
Vaporizing foil actuator welding (VFAW),, SPH, Process-property relationship, Al/Steel, 3-stack
Subjects based on RSWK
Folienvaporisation, Aluminium, Stahl, Verbindungstechnik, Feasibility-Studie