Rapid solidification joining of non-ferrous materials

摘要

Rapid solidification welding processes have several advantages over high heat input welding processes including narrow weld width, small heat affected zones, minimal segregation and, fast cycle times. Unfortunately non-destructive methods to determine weld quality are expensive and ineffective in these very thin welds. As part of an on line weld quality control weld evaluation program, a thermodynamic model was developed to predict the minimum energy required to form welds in various materials including aluminum, copper, brass, silver, titanium and titanium aluminide. Finite element residual weld stress predictions were made for capacitor discharge welded joints. Crack count and flaw content were used as weld quality indicators and compared to predicted values. Among the interesting results observed in this study was the low 9J/mm~2 optimum silver to brass weld energy and the high 2,400 MPa residual stress prediction for titanium aluminide welds. These predictions correlated with observed weld cracking.