On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions
This novel research aims to examine the macro and microstructural bonding region development during magnetic pulse welding (MPW) of dissimilar additive manufactured (AM) laser powder-bed fusion (L-PBF) AlSi10Mg rod and AA6060-T6 wrought tube, using both optimal- and high-energy welding conditions. F...
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| Format: | Article |
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MDPI AG
2020-09-01
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| Series: | Metals |
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| Online Access: | https://www.mdpi.com/2075-4701/10/9/1235 |
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| author | Moshe Nahmany Victor Shribman Shlomo Levi Dana Ashkenazi Adin Stern |
| author_facet | Moshe Nahmany Victor Shribman Shlomo Levi Dana Ashkenazi Adin Stern |
| author_sort | Moshe Nahmany |
| collection | DOAJ |
| description | This novel research aims to examine the macro and microstructural bonding region development during magnetic pulse welding (MPW) of dissimilar additive manufactured (AM) laser powder-bed fusion (L-PBF) AlSi10Mg rod and AA6060-T6 wrought tube, using both optimal- and high-energy welding conditions. For that purpose, various joint characterisation methods were applied. It is demonstrated that high-quality hermetic welds are achievable with adjusted MPW process parameters. The macroscale analysis has shown that the joint interfaces are deformed to a waveform shape; the interface is starting relatively planar, with waves forming and growing in the welding direction. The observed thickening of the flyer’s wall after welding is the result of its diametral inward deformation, taking place during the process. A slight increase in microhardness was adjacent to the faying interfaces; a higher increase was measured on the AlSi10Mg material side, while a smaller one was observed on the AA6060 side. Along the wavy interfaces, resolidified “pockets” of material or occasionally discontinuous short layers exhibiting different morphologies, were detected. The jet residues are typically located towards the end of the weld, confirming a temperature rise that exceeds the melting temperature of both alloys. Far from the weld zone, extremely thin-film deposits were clearly observed on the inner flyer surfaces. The formation of isolated Si particles and thin-film deposits may point out that the local increase in temperatures leads to melting or even evaporation vaporisation of superficial layers from the colliding parts. It is worth noting that this type of jet residue was discovered for the first time in the present research. The current research work is expected to provide an understanding of weld formation mechanisms of additively manufactured parts to conventional wrought parts conforming to existing wrought/wrought weld knowledge. |
| first_indexed | 2024-03-10T16:20:25Z |
| format | Article |
| id | doaj.art-382df287312d4aa0a482522a186ddd04 |
| institution | Directory Open Access Journal |
| issn | 2075-4701 |
| language | English |
| last_indexed | 2024-03-10T16:20:25Z |
| publishDate | 2020-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Metals |
| spelling | doaj.art-382df287312d4aa0a482522a186ddd042023-11-20T13:40:49ZengMDPI AGMetals2075-47012020-09-01109123510.3390/met10091235On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding ConditionsMoshe Nahmany0Victor Shribman1Shlomo Levi2Dana Ashkenazi3Adin Stern4Department of Materials, Nuclear Research Center-Negev, Beer Sheva 8410900, IsraelBmax Srl., Hod Hasharon 4501306, IsraelDepartment of Materials, Nuclear Research Center-Negev, Beer Sheva 8410900, IsraelSchool of Mechanical Engineering, Tel Aviv University, Ramat Aviv 6997801, IsraelDepartment of Materials Engineering, Ben-Gurion University of the Negev, Beer Sheva 8410501, IsraelThis novel research aims to examine the macro and microstructural bonding region development during magnetic pulse welding (MPW) of dissimilar additive manufactured (AM) laser powder-bed fusion (L-PBF) AlSi10Mg rod and AA6060-T6 wrought tube, using both optimal- and high-energy welding conditions. For that purpose, various joint characterisation methods were applied. It is demonstrated that high-quality hermetic welds are achievable with adjusted MPW process parameters. The macroscale analysis has shown that the joint interfaces are deformed to a waveform shape; the interface is starting relatively planar, with waves forming and growing in the welding direction. The observed thickening of the flyer’s wall after welding is the result of its diametral inward deformation, taking place during the process. A slight increase in microhardness was adjacent to the faying interfaces; a higher increase was measured on the AlSi10Mg material side, while a smaller one was observed on the AA6060 side. Along the wavy interfaces, resolidified “pockets” of material or occasionally discontinuous short layers exhibiting different morphologies, were detected. The jet residues are typically located towards the end of the weld, confirming a temperature rise that exceeds the melting temperature of both alloys. Far from the weld zone, extremely thin-film deposits were clearly observed on the inner flyer surfaces. The formation of isolated Si particles and thin-film deposits may point out that the local increase in temperatures leads to melting or even evaporation vaporisation of superficial layers from the colliding parts. It is worth noting that this type of jet residue was discovered for the first time in the present research. The current research work is expected to provide an understanding of weld formation mechanisms of additively manufactured parts to conventional wrought parts conforming to existing wrought/wrought weld knowledge.https://www.mdpi.com/2075-4701/10/9/1235additive manufacturing laser powder-bed fusionAlSi10Mg alloymagnetic pulse weldingoptimal-energy welding conditionshigh-energy welding conditionswrought AA6060-T6 |
| spellingShingle | Moshe Nahmany Victor Shribman Shlomo Levi Dana Ashkenazi Adin Stern On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions Metals additive manufacturing laser powder-bed fusion AlSi10Mg alloy magnetic pulse welding optimal-energy welding conditions high-energy welding conditions wrought AA6060-T6 |
| title | On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions |
| title_full | On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions |
| title_fullStr | On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions |
| title_full_unstemmed | On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions |
| title_short | On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions |
| title_sort | on additive manufactured alsi10mg to wrought aa6060 t6 characterisation of optimal and high energy magnetic pulse welding conditions |
| topic | additive manufacturing laser powder-bed fusion AlSi10Mg alloy magnetic pulse welding optimal-energy welding conditions high-energy welding conditions wrought AA6060-T6 |
| url | https://www.mdpi.com/2075-4701/10/9/1235 |
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