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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.

Interface morphology for four of the aluminum-steel configurations welded under this program

Mechanical testing results: (left) actual aluminum-steel weld samples tested before and after corrosion, (right) lap shear strengths of various types of VFAW samples. Asterisk (*) represents parent aluminum’s tensile strength.