Development of Fill Impact Welding technique for metal additive manufacturing
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Date
2025-08-26
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Abstract
Metal additive manufacturing typically utilizes powder as feed. Fill impact welding, uses
dime-sized pieces of sheet metal launched at high speeds to impact and weld to the metallic
substrate. The driving force can be generated by several means, including vaporizing foil
actuators used in this work. A custom impact welding fixture was built to launch 0.5 mm thick
and 6.35 mm diameter flat circular metallic disks (flyers) to speeds greater than 500 m/s over
a travel distance of 5 millimeters. The flyers impacted target plates placed at fixed relative
angles. Fully welded interfaces were observed via cross sectional metallography as well as
non-destructive evaluation methods of ultrasonic testing. It was demonstrated that titanium
flyers can be reproducibly welded to copper for a certain set of parameters. Furthermore, the
impact velocity was found to be controllable and repeatable for various input energies from
the capacitor bank power system. For example, for 2.0kJ input energy shots, the average peak
velocities of the flyer were measured to be 800 m/s with a variation of less than 3%.
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Keywords
additive, NDE, welding, repair
Subjects based on RSWK
Rapid Prototyping <Fertigung>, Fülldrahtelektrode, Schweißen, Metall, Zerstörungsfreie Werkstoffprüfung, Ultraschall