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- Explosive welding of aluminium to stainless steel using carbon steel and niobium interlayersPublication . Carvalho, Gustavo; Galvão, Ivan; Mendes, R.; Leal, R. M.; Loureiro, AltinoThis work aimed to study aluminium to stainless steel explosive welds produced using two different interlayers: carbon steel and niobium. The use of each interlayer was analysed and compared microstructurally and mechanically using many characterisation techniques. The final joints using both interlayers presented favourable interfacial microstructure: waves on both interfaces. However, the joint using the carbon steel interlayer showed the best mechanical properties compared to the joints using the niobium interlayer. All interfaces found on both welds were wavy. However, depending on the metallic alloy combination, the shape of the wave is completely different. The results suggest that the shape of the waves is influenced by the shock impedance mismatch of the materials being welded. The impedance mismatch parameter (IMP) developed for explosive welding in this work proved to be a compelling method to order metallic combinations in a single axis to estimate the tendency to form typical or curled waves. Typical symmetrical waves tend to develop less quantity of IMCs than curled waves. However, the mechanical tests performed did not detect differences that could have been caused by this difference.
- Friction stir welding and explosive welding of aluminum/copper: process analysisPublication . Carvalho, G. H. S. F. L.; Galvão, Ivan; Mendes, R.; Leal, Rui; Loureiro, AltinoThe 6082 aluminum alloy was welded to copper-DHP by friction stir welding and explosive welding. The effect of each welding process on the microstructural evolution, the intermetallic phases distribution, and the mechanical behavior of both types of welds was analyzed and compared. The microstructural changes proved to be much more expressive in friction stir welding due to the larger area under plastic deformation, the stirring and mixing of the alloys, the longer time under high temperature, and the longer interaction times between the base materials during welding. As explosive welding process is much faster, it avoids extensive microstructural changes and significant interaction of the materials, reducing the intermetallic volumes and their distribution along the interface. The friction stir welds presented Cu-rich intermetallics while the explosive welds presented Al-rich intermetallics. For alloys that can easily form brittle intermetallic phases, excessive interaction during the welding process leads to a very poor mechanical behavior of the joints.
- Impact welding of materialsPublication . Galvão, Ivan; Loureiro, Altino; Mendes, RicardoRecent industrial criteria, focused on obtaining increasingly efficient structures, require the production of multimaterial components. However, the manufacturing requirements of these components are not met by conventional welding techniques. Alternative solid-state technologies, such as friction or impact-based processes, must be considered. Impact welding processes have the advantage of presenting a very short cycle time, which minimises the interaction of the materials under high temperature. This fact strongly contributes to reducing the formation of brittle intermetallic compounds (IMCs), i.e., one of the main concerns of welding dissimilar materials. Moreover, as the influence of the welding process is confined to a very narrow band around the materials interface, similar and dissimilar welds with high-strength bonding and a minimal heat-affected zone can be produced. The impact welding family encompasses different welding processes, such as explosion welding, magnetic pulse welding, vaporising foil actuator welding, and laser impact welding. Although these processes share the main operating principle, consisting of a high-velocity collision between a flyer and a target, they differ in the way the flyer is accelerated. These processes also present very different length scales, providing the impact welding family with a broad applicability range. The technical interest of impact welding is driving the ongoing development of many scientific studies, which are essential to optimise the current manufacturing processes by developing new welding strategies and solutions. The present special issue presents a sample of the cutting-edge research that is being conducted on the multidisciplinary field of impact welding.
- Influence of base material properties on copper and aluminium-copper explosive weldsPublication . Carvalho, Gustavo; Galvão, Ivan; Mendes, R.; Leal, Rui; Loureiro, AltinoThe influence of base material properties on the interfacial phenomena in copper and aluminium-copper explosive welds was studied. Two explosive mixtures with different detonation velocities were tested. Sound aluminium-copper joints with effective bonding were achieved by using an explosive mixture with a lower detonation velocity. High energy explosives led to extensive interfacial melting, preventing the production of consistent dissimilar welds. Unlike to the similar copper joints, the aluminium-copper welds presented very asymmetrical interfacial waves, rich in intermetallic phases and displaying a curled morphology. The interaction of the materials in dissimilar welding was found to be completely different depending on the positioning of each alloy in the joint, i.e. positioned as the flyer or as the baseplate.
- Weldability of aluminium-copper in explosive weldingPublication . Carvalho, G. H. S. F. L.; Galvão, Ivan; Mendes, R.; Leal, Rui; Loureiro, AltinoA large number of aluminium-copper explosive welds were produced under different welding conditions to perform a broad analysis of the weldability of this combination. The influence of the explosive mixture and the relative positioning of the plates on the welding results were analysed. When the aluminium alloy is positioned as the flyer plate, continuous interfacial melting occurred under the low values of energy lost by the collision, and collision point velocity. This proved that the weldability of the aluminium-copper combination is higher when the copper is positioned as the flyer. A mismatch between the experimental results and the existing theories that define the requirements for achieving consistent welds was noticed. Especially for welds produced using the aluminium alloy as the flyer, the experiments proved to be more restrictive than the theories. These theories, despite being widely applied in dissimilar welding literature, present several limitations concerning aluminium-copper welding. New approaches considering the formation of intermetallic phases at the interface, the properties of both welded metals, and/or the difference in their properties should be developed.