Benchmarking and Refining the Vaporizing Foil Actuator Spot Welding Process
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Date
2016-04-27
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Abstract
Impact spot welding implemented by the vaporizing foil actuator welding method has been
studied. With significantly lower input energy levels as compared to resistance spot
welding, similar and dissimilar lap welding of aluminium alloys (AA) of types 5052 and
7075 was implemented. The dissimilar welds between 2 mm thick AA5052 and 2.3 mm
thick AA7075 were created with 4 kilojoules input energy, whereas the similar welds
between 1 mm thick AA5052 sheets required only 0.6 kilojoules. Flyer sheet velocities of
approximately 750 m/s were measured with a PDV system. Microhardness measurements,
performed across the dissimilar weld interfaces, showed no softening of the base materials
due to the welding process. A few distinct welding configurations were investigated for
improving process feasibility and obtaining the highest possible weld strength. Lap shear
tests and pry tests revealed that the configuration of the starting weld geometry greatly
affected weld quality.
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Keywords
aluminum, photonic Doppler velocimetry, welding