Collision Welding of Dissimilar Materials by Vaporizing Foil Actuator
Principal Investigators: Glenn Daehn, Anupam Vivek
Graduate student: Bert Liu
Under this program (10/2013-6/2016) feasibility of using Vaporizing Foil Actuator Welding (VFAW) technique for welding dissimilar material combinations of aluminum, steel, and magnesium alloys were tested. Seventeen material systems were screened using VFAW in different configurations during the first year. Four additional combinations of high-performance aluminum and steel alloys were investigated during the second year. Of all the screened combinations, seven were selected for further study with corrosion testing and mechanical testing. Half of the e-coated aluminum/iron (Al/Fe) samples retained >90% lap-shear strength after 30 cycles of ASTM B-117 salt-spray testing. Thicker materials such as 2.0-mm AA6061-T4 and high-strength materials such as 1500 MPa boron steel were welded successfully, and strong joints were achieved such that failure occurred in the base material, away from the weld, during lap-shear testing.