The Experts below are selected from a list of 324 Experts worldwide ranked by ideXlab platform
Filippo Berto - One of the best experts on this subject based on the ideXlab platform.
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microstructural and mechanical characterisation of a second generation hybrid Metal Extrusion bonding aluminium steel butt joint
Materials Characterization, 2021Co-Authors: Tina Bergh, Lise Sandnes, Filippo Berto, O Grong, Duncan N. Johnstone, Randi Holmestad, Paul A. Midgley, Per Erik VullumAbstract:Abstract Hybrid Metal Extrusion & bonding (HYB) is a joining method that enables solid-state bonding by combining addition of aluminium filler material through continuous Extrusion with pressure exerted by a rotating steel tool. This work presents mechanical and microstructural characterisation of a second generation HYB butt joint of aluminium alloy 6082 and structural steel S355. The ultimate tensile strength was measured to be in the range of 184–220 MPa, which corresponds to 60–72% joint efficiency. Digital image correlation analysis of the strain development during tensile testing revealed that root cracks formed, before the final fracture ran close to the aluminium-steel interface. A significant amount of residual aluminium was found on the steel fracture surface, especially in regions that experienced higher pressure during joining. Scanning and transmission electron microscopy revealed that the bond strength could be attributed to a combination of microscale mechanical interlocking and a discontinuous nanoscale interfacial Al-Fe-Si interMetallic phase layer. Analysis of scanning electron diffraction data acquired in a tilt series, indicated that the polycrystalline interMetallic phase layer contained the cubic αc phase. The results give insight into the bonding mechanisms of aluminium-steel joints and into the performance of HYB joints, which may be used to better understand and further develop aluminium-steel joining processes.
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Interface Microstructure and Tensile Properties of a Third Generation Aluminium-Steel Butt Weld Produced Using the Hybrid Metal Extrusion & Bonding (HYB) Process
Materials Science and Engineering: A, 2021Co-Authors: Lise Sandnes, Øystein Grong, Tina Bergh, Randi Holmestad, Per Erik Vullum, Filippo BertoAbstract:Abstract The Hybrid Metal Extrusion & Bonding (HYB) process is a patented solid state joining method for Metals which utilizes filler material additions to consolidate the weld. In the present investigation the interface microstructure and tensile properties of a 4 mm thick joint, belonging to the third generation Al-steel HYB butt welds, are characterized. The mechanical testing shows that the HYB weld exhibits excellent tensile properties, displaying ultimate tensile strength values in the range from 238 to 266 MPa. Moreover, supplementary digital image correlation analysis of the strain evolution occurring during tensile testing reveals that all plastic deformation is localized to the soft heat-affected zone on the aluminium side of the joint, leading to necking and final fracture in the aluminium. Scanning and transmission electron microscopy examinations of the Al-steel interface show that bonding occurs by a combination of microscale mechanical interlocking and interMetallic compound formation. The interMetallic layer has a thickness varying between 0.1 and 1 μm and is composed of Al-Fe-Si crystals. This makes the butt joint highly resistant against interfacial cracking. The subsequent benchmarking against commercial fusion and solid state welding methods reveals that the tensile properties of the Al-steel HYB weld even surpass those reported for comparable friction stir welds. At the same time, the HYB process allows butt welding to be performed at much higher speeds compared to friction stir welding, without compromising the mechanical integrity of the weldment.
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A Semi-Analytical Model for the Heat Generation during Hybrid Metal Extrusion and Bonding (HYB).
Materials (Basel Switzerland), 2020Co-Authors: Francesco Leoni, Øystein Grong, Paolo Ferro, Filippo BertoAbstract:Hybrid Metal Extrusion and Bonding (HYB) is a novel solid-state welding method for Metals and alloys that utilises continuous Extrusion as a technique to enable aluminium filler Metal additions. In the present study, a new semi-analytical model for the heat generation during aluminium butt welding is presented. As a starting point, the classical Rosenthal thin plate solution for the pseudo-steady-state temperature distribution around a fully penetrating line source is invoked. Then, the associated heat generation is calculated by considering the individual contributions from the tip of the rotating pin, the pin shoulder, and the filler Metal additions on the net power input. In a calibrated form, the model yields thermal efficiency factors that are in close agreement with those obtained from more sophisticated finite element analyses but with considerably less computational effort.
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Microstructural and mechanical characterisation of a second generation hybrid Metal Extrusion & bonding aluminium-steel butt joint
Materials Characterization, 2020Co-Authors: Tina Bergh, Lise Sandnes, Øystein Grong, Filippo Berto, Duncan N. Johnstone, Randi Holmestad, Paul A. Midgley, Per Erik VullumAbstract:Abstract Hybrid Metal Extrusion & bonding (HYB) is a joining method that enables solid-state bonding by combining addition of aluminium filler material through continuous Extrusion with pressure exerted by a rotating steel tool. This work presents mechanical and microstructural characterisation of a second generation HYB butt joint of aluminium alloy 6082 and structural steel S355. The ultimate tensile strength was measured to be in the range of 184–220 MPa, which corresponds to 60–72% joint efficiency. Digital image correlation analysis of the strain development during tensile testing revealed that root cracks formed, before the final fracture ran close to the aluminium-steel interface. A significant amount of residual aluminium was found on the steel fracture surface, especially in regions that experienced higher pressure during joining. Scanning and transmission electron microscopy revealed that the bond strength could be attributed to a combination of microscale mechanical interlocking and a discontinuous nanoscale interfacial Al-Fe-Si interMetallic phase layer. Analysis of scanning electron diffraction data acquired in a tilt series, indicated that the polycrystalline interMetallic phase layer contained the cubic αc phase. The results give insight into the bonding mechanisms of aluminium-steel joints and into the performance of HYB joints, which may be used to better understand and further develop aluminium-steel joining processes.
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Correction to: Exploring the hybrid Metal Extrusion and bonding process for butt welding of Al–Mg–Si alloys
The International Journal of Advanced Manufacturing Technology, 2018Co-Authors: Lise Sandnes, Torgeir Welo, Øystein Grong, Jan Torgersen, Filippo BertoAbstract:The article Exploring the hybrid Metal Extrusion and bonding process for butt welding of Al–Mg–Si alloys, written by Lise Sandnes, Øystein Grong, Jan Torgersen, Torgeir Welo and Filippo Berto, was originally published electronically on the publisher’s internet portal (currently SpringerLink).
Martin Steinert - One of the best experts on this subject based on the ideXlab platform.
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On the mechanical integrity of AA6082 3D structures deposited by hybrid Metal Extrusion & bonding additive manufacturing
Journal of Materials Processing Technology, 2020Co-Authors: Jorgen Blindheim, Torgeir Welo, Øystein Grong, Martin SteinertAbstract:Abstract Hybrid Metal Extrusion and Bonding Additive Manufacturing (HYB-AM) is a new solid-state process for the production of 3D Metal structures. In HYB-AM, the wire feedstock is continuously processed through an extruder and deposited in a stringer-by-stringer manner to form layers and eventually a near net-shape component. In this work, the layer bonding of AA6082 samples produced by this process has been investigated by means of tensile testing, hardness measurements and microscope analyses. Furthermore, a novel method for the fabrication of miniature tensile specimens for assessing the bond strength across the layers is presented and applied. The test results reveal that the ultimate tensile strength is approaching that of the substrate material of the same alloy, yet with a somewhat lower elongation prior to fracture. Microscope analyses show that the bonded interfaces are fully dense; however, the fracture surfaces reveal regions of kissing-bonds and lack of bonding. Still, these preliminary investigations indicate that the HYB-AM process, upon further optimization, has the potential of processing high quality aluminum alloy components.
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First demonstration of a new additive manufacturing process based on Metal Extrusion and solid-state bonding
The International Journal of Advanced Manufacturing Technology, 2019Co-Authors: Jorgen Blindheim, Torgeir Welo, Martin SteinertAbstract:In this paper, a new additive manufacturing (AM) process based on Extrusion and solid-state bonding is presented. The process uses Metal feedstock wire which is processed in a continuous rotary extruder in order to disperse the surface oxides of the feedstock and to provide the required bonding pressure. Simultaneously, the die outlet is scraping the contact surface to provide an oxide-free interface between the extrudate and the substrate. Optical analyses of samples from a layered structure produced from AA6082 reveal that the stringers are fully merged; however, some voids and cracks are observed between the individual stringers. Still, this initial demonstration indicates that the process, upon further development, has high potential of producing near-net-shape parts at high deposition rates.
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Investigating the mechanics of hybrid Metal Extrusion and bonding additive manufacturing by FEA
Metals, 2019Co-Authors: Jorgen Blindheim, Torgeir Welo, Martin SteinertAbstract:Hybrid Metal Extrusion & Bonding Additive Manufacturing (HYB-AM) is a hybrid manufacturing technology for the deposition of layered Metal structures. This new deposition process is a complex Metal forming operation, yet there is significant lack of knowledge regarding the governing mechanisms. In this work, we have used finite element analysis (FEA) to study material flow in the extruder, as well as the conditions at the interfaces of the deposited extrudate and the substrate, aiming to identify and characterize the process parameters involved. Analysis of the material flow shows that the Extrusion pressure is virtually independent of the deposition rate. Furthermore, from the simulations of the material deposition sequence, it is clearly visible how the contact pressure at the interface will drop below the bonding threshold if the feed speed is too high relative to the material flow through the die. The reduced pressure also leads to the formation of a ‘gas-pocket’ inside the die, thus further degrading the conditions for bonding. The analyses of the process have provided valuable insights for the further development and industrialization of the process.
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Hybrid Metal Extrusion & Bonding (HYB) - a new technology for solid-state additive manufacturing of aluminium components
Procedia Manufacturing, 2018Co-Authors: Jorgen Blindheim, Torgeir Welo, Ulf Roar Aakenes, Øystein Grong, Martin SteinertAbstract:Abstract This paper demonstrates a concept for a new additive manufacturing process for aluminium alloys, based on the Hybrid Metal Extrusion & Bonding (HYB) technology, along with the potential for further development of the process. The process is capable of producing near net shape structures at high deposition rates, utilizing Metallic bonding to consolidate the feedstock to the substrate in the solid-state. The aluminium feedstock wire is processed through a specially designed extruder, which serves the purpose of dispersing inherent oxides of both the feedstock and the substrate. At the same time it provides sufficient pressure for Metallic bonding to occur. The process has been tested on a concept level by successfully depositing a two-layered structure of commercial purity aluminium.
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hybrid Metal Extrusion bonding hyb a new technology for solid state additive manufacturing of aluminium components
Procedia Manufacturing, 2018Co-Authors: Jorgen Blindheim, Torgeir Welo, Ulf Roar Aakenes, O Grong, Martin SteinertAbstract:Abstract This paper demonstrates a concept for a new additive manufacturing process for aluminium alloys, based on the Hybrid Metal Extrusion & Bonding (HYB) technology, along with the potential for further development of the process. The process is capable of producing near net shape structures at high deposition rates, utilizing Metallic bonding to consolidate the feedstock to the substrate in the solid-state. The aluminium feedstock wire is processed through a specially designed extruder, which serves the purpose of dispersing inherent oxides of both the feedstock and the substrate. At the same time it provides sufficient pressure for Metallic bonding to occur. The process has been tested on a concept level by successfully depositing a two-layered structure of commercial purity aluminium.
Tai Chiu Lee - One of the best experts on this subject based on the ideXlab platform.
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Numerical analysis of the sheet Metal Extrusion process
Finite Elements in Analysis and Design, 2005Co-Authors: P. F. Zheng, Luen Chow Chan, Tai Chiu LeeAbstract:Sheet Metal Extrusion is a process in which the Extrusion punch penetrates one surface of the sheet Metal material to cause it to extrude and flow toward the outlet of the die. In fact, this process is a combined process in which both Extrusion and penetration occur at the same time. The process can be seen in production processes, such as in the forming of a protruding part on a strip material, in the pre-forming of a staged hole in a forming step with a progressive die, and in the forming of the extruded part in a combined fine-blanking and Extrusion process. This paper presents the characteristics of the process and gives a detailed analysis of it with the finite element method. According to the results, the mesh distortion, the field of material flow, and the distributions of the stress and strain can be predicted. Analysing the results from simulation, it is proposed that the extruded material can be divided into five areas according to their different features of deformation. In addition, the material in the areas of deformation can further be divided into three parts according to their different features of compression and elongation. The location of the fracture has been predicted from simulations. Some experiments have been carried out to verify the simulated results.
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Numerical simulation of a sheet Metal Extrusion process by using thermal-mechanical coupling EAS FEM
Journal of University of Science and Technology Beijing, 2002Co-Authors: Zhe Chen, Tai Chiu Lee, Chak Yin TangAbstract:The thermal-mechanical coupling finite element method (FEM) was used to simulate a non-isothermal sheet Metal Extrusion process. On the basis of the finite plasticity consistent with multiplicative decomposition of the deformation gradient, the enhanced assumed strain (EAS) FEM was applied to carry out the numerical simulation. In order to make the computation reliable and avoid hourglass mode in the EAS element under large compressive strains, an alterative form of the original enhanced deformation gradient was employed. In addition, reduced factors were used in the computation of the element local internal parameters and the enhanced part of elemental stiffness. Numerical resultsshow that the hourglass can be avoided in compression region. In the thermal phase, the boundary energy dissipation due to heat convection was taken into account. As an example, a circular steel plate protruded by cylindrical punch was simulated. The step-wise decoupled strategyis adopted to handle coupling between mechanical deformation and the temperature variation. By comparing with the experimental results, thenumerical simulation was verified.
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Simulation of the sheet Metal Extrusion process by the enhanced assumed strain finite element method
Journal of Materials Processing Technology, 1999Co-Authors: Zhe Chen, Luen Chow Chan, Chak Yin Tang, Tai Chiu LeeAbstract:Abstract The Extrusion process of a steel plate has been simulated by the geometrically non-linear enhanced assumed strain finite element method. An enhanced strain field has been added to the conventional axisymmetric four nodes element to avoid volumetric locking in the plastic range. In order to achieve volume constraint closely, the enhanced deformation gradient has been constructed in the rate form. The standard Newton–Raphson iteration method together with the corresponding consistent tangent operator have been used to solve the incremental equilibrium equations. The local integration of the finite strain J 2 -flow theory has been carried out by the elastic predictor and plastic corrector return mapping algorithm. The material constitutive equation used takes the effects of strain hardening and damage softening into account. In the solution process, a line search technique has been used to ensure computational convergence. The computed profile of the protruded workpiece has been found to be in good agreement with the actual profile. The results also show that damage softening has a remarkable influence on the limit strain of the Extrusion process. It may be concluded that the enhanced assumed strain finite element method can be used to analyze sheet Metal Extrusion.
Øystein Grong - One of the best experts on this subject based on the ideXlab platform.
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Interface Microstructure and Tensile Properties of a Third Generation Aluminium-Steel Butt Weld Produced Using the Hybrid Metal Extrusion & Bonding (HYB) Process
Materials Science and Engineering: A, 2021Co-Authors: Lise Sandnes, Øystein Grong, Tina Bergh, Randi Holmestad, Per Erik Vullum, Filippo BertoAbstract:Abstract The Hybrid Metal Extrusion & Bonding (HYB) process is a patented solid state joining method for Metals which utilizes filler material additions to consolidate the weld. In the present investigation the interface microstructure and tensile properties of a 4 mm thick joint, belonging to the third generation Al-steel HYB butt welds, are characterized. The mechanical testing shows that the HYB weld exhibits excellent tensile properties, displaying ultimate tensile strength values in the range from 238 to 266 MPa. Moreover, supplementary digital image correlation analysis of the strain evolution occurring during tensile testing reveals that all plastic deformation is localized to the soft heat-affected zone on the aluminium side of the joint, leading to necking and final fracture in the aluminium. Scanning and transmission electron microscopy examinations of the Al-steel interface show that bonding occurs by a combination of microscale mechanical interlocking and interMetallic compound formation. The interMetallic layer has a thickness varying between 0.1 and 1 μm and is composed of Al-Fe-Si crystals. This makes the butt joint highly resistant against interfacial cracking. The subsequent benchmarking against commercial fusion and solid state welding methods reveals that the tensile properties of the Al-steel HYB weld even surpass those reported for comparable friction stir welds. At the same time, the HYB process allows butt welding to be performed at much higher speeds compared to friction stir welding, without compromising the mechanical integrity of the weldment.
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A Semi-Analytical Model for the Heat Generation during Hybrid Metal Extrusion and Bonding (HYB).
Materials (Basel Switzerland), 2020Co-Authors: Francesco Leoni, Øystein Grong, Paolo Ferro, Filippo BertoAbstract:Hybrid Metal Extrusion and Bonding (HYB) is a novel solid-state welding method for Metals and alloys that utilises continuous Extrusion as a technique to enable aluminium filler Metal additions. In the present study, a new semi-analytical model for the heat generation during aluminium butt welding is presented. As a starting point, the classical Rosenthal thin plate solution for the pseudo-steady-state temperature distribution around a fully penetrating line source is invoked. Then, the associated heat generation is calculated by considering the individual contributions from the tip of the rotating pin, the pin shoulder, and the filler Metal additions on the net power input. In a calibrated form, the model yields thermal efficiency factors that are in close agreement with those obtained from more sophisticated finite element analyses but with considerably less computational effort.
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On the mechanical integrity of AA6082 3D structures deposited by hybrid Metal Extrusion & bonding additive manufacturing
Journal of Materials Processing Technology, 2020Co-Authors: Jorgen Blindheim, Torgeir Welo, Øystein Grong, Martin SteinertAbstract:Abstract Hybrid Metal Extrusion and Bonding Additive Manufacturing (HYB-AM) is a new solid-state process for the production of 3D Metal structures. In HYB-AM, the wire feedstock is continuously processed through an extruder and deposited in a stringer-by-stringer manner to form layers and eventually a near net-shape component. In this work, the layer bonding of AA6082 samples produced by this process has been investigated by means of tensile testing, hardness measurements and microscope analyses. Furthermore, a novel method for the fabrication of miniature tensile specimens for assessing the bond strength across the layers is presented and applied. The test results reveal that the ultimate tensile strength is approaching that of the substrate material of the same alloy, yet with a somewhat lower elongation prior to fracture. Microscope analyses show that the bonded interfaces are fully dense; however, the fracture surfaces reveal regions of kissing-bonds and lack of bonding. Still, these preliminary investigations indicate that the HYB-AM process, upon further optimization, has the potential of processing high quality aluminum alloy components.
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Microstructural and mechanical characterisation of a second generation hybrid Metal Extrusion & bonding aluminium-steel butt joint
Materials Characterization, 2020Co-Authors: Tina Bergh, Lise Sandnes, Øystein Grong, Filippo Berto, Duncan N. Johnstone, Randi Holmestad, Paul A. Midgley, Per Erik VullumAbstract:Abstract Hybrid Metal Extrusion & bonding (HYB) is a joining method that enables solid-state bonding by combining addition of aluminium filler material through continuous Extrusion with pressure exerted by a rotating steel tool. This work presents mechanical and microstructural characterisation of a second generation HYB butt joint of aluminium alloy 6082 and structural steel S355. The ultimate tensile strength was measured to be in the range of 184–220 MPa, which corresponds to 60–72% joint efficiency. Digital image correlation analysis of the strain development during tensile testing revealed that root cracks formed, before the final fracture ran close to the aluminium-steel interface. A significant amount of residual aluminium was found on the steel fracture surface, especially in regions that experienced higher pressure during joining. Scanning and transmission electron microscopy revealed that the bond strength could be attributed to a combination of microscale mechanical interlocking and a discontinuous nanoscale interfacial Al-Fe-Si interMetallic phase layer. Analysis of scanning electron diffraction data acquired in a tilt series, indicated that the polycrystalline interMetallic phase layer contained the cubic αc phase. The results give insight into the bonding mechanisms of aluminium-steel joints and into the performance of HYB joints, which may be used to better understand and further develop aluminium-steel joining processes.
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Correction to: Exploring the hybrid Metal Extrusion and bonding process for butt welding of Al–Mg–Si alloys
The International Journal of Advanced Manufacturing Technology, 2018Co-Authors: Lise Sandnes, Torgeir Welo, Øystein Grong, Jan Torgersen, Filippo BertoAbstract:The article Exploring the hybrid Metal Extrusion and bonding process for butt welding of Al–Mg–Si alloys, written by Lise Sandnes, Øystein Grong, Jan Torgersen, Torgeir Welo and Filippo Berto, was originally published electronically on the publisher’s internet portal (currently SpringerLink).
Jorgen Blindheim - One of the best experts on this subject based on the ideXlab platform.
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On the mechanical integrity of AA6082 3D structures deposited by hybrid Metal Extrusion & bonding additive manufacturing
Journal of Materials Processing Technology, 2020Co-Authors: Jorgen Blindheim, Torgeir Welo, Øystein Grong, Martin SteinertAbstract:Abstract Hybrid Metal Extrusion and Bonding Additive Manufacturing (HYB-AM) is a new solid-state process for the production of 3D Metal structures. In HYB-AM, the wire feedstock is continuously processed through an extruder and deposited in a stringer-by-stringer manner to form layers and eventually a near net-shape component. In this work, the layer bonding of AA6082 samples produced by this process has been investigated by means of tensile testing, hardness measurements and microscope analyses. Furthermore, a novel method for the fabrication of miniature tensile specimens for assessing the bond strength across the layers is presented and applied. The test results reveal that the ultimate tensile strength is approaching that of the substrate material of the same alloy, yet with a somewhat lower elongation prior to fracture. Microscope analyses show that the bonded interfaces are fully dense; however, the fracture surfaces reveal regions of kissing-bonds and lack of bonding. Still, these preliminary investigations indicate that the HYB-AM process, upon further optimization, has the potential of processing high quality aluminum alloy components.
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First demonstration of a new additive manufacturing process based on Metal Extrusion and solid-state bonding
The International Journal of Advanced Manufacturing Technology, 2019Co-Authors: Jorgen Blindheim, Torgeir Welo, Martin SteinertAbstract:In this paper, a new additive manufacturing (AM) process based on Extrusion and solid-state bonding is presented. The process uses Metal feedstock wire which is processed in a continuous rotary extruder in order to disperse the surface oxides of the feedstock and to provide the required bonding pressure. Simultaneously, the die outlet is scraping the contact surface to provide an oxide-free interface between the extrudate and the substrate. Optical analyses of samples from a layered structure produced from AA6082 reveal that the stringers are fully merged; however, some voids and cracks are observed between the individual stringers. Still, this initial demonstration indicates that the process, upon further development, has high potential of producing near-net-shape parts at high deposition rates.
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Investigating the mechanics of hybrid Metal Extrusion and bonding additive manufacturing by FEA
Metals, 2019Co-Authors: Jorgen Blindheim, Torgeir Welo, Martin SteinertAbstract:Hybrid Metal Extrusion & Bonding Additive Manufacturing (HYB-AM) is a hybrid manufacturing technology for the deposition of layered Metal structures. This new deposition process is a complex Metal forming operation, yet there is significant lack of knowledge regarding the governing mechanisms. In this work, we have used finite element analysis (FEA) to study material flow in the extruder, as well as the conditions at the interfaces of the deposited extrudate and the substrate, aiming to identify and characterize the process parameters involved. Analysis of the material flow shows that the Extrusion pressure is virtually independent of the deposition rate. Furthermore, from the simulations of the material deposition sequence, it is clearly visible how the contact pressure at the interface will drop below the bonding threshold if the feed speed is too high relative to the material flow through the die. The reduced pressure also leads to the formation of a ‘gas-pocket’ inside the die, thus further degrading the conditions for bonding. The analyses of the process have provided valuable insights for the further development and industrialization of the process.
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Hybrid Metal Extrusion & Bonding (HYB) - a new technology for solid-state additive manufacturing of aluminium components
Procedia Manufacturing, 2018Co-Authors: Jorgen Blindheim, Torgeir Welo, Ulf Roar Aakenes, Øystein Grong, Martin SteinertAbstract:Abstract This paper demonstrates a concept for a new additive manufacturing process for aluminium alloys, based on the Hybrid Metal Extrusion & Bonding (HYB) technology, along with the potential for further development of the process. The process is capable of producing near net shape structures at high deposition rates, utilizing Metallic bonding to consolidate the feedstock to the substrate in the solid-state. The aluminium feedstock wire is processed through a specially designed extruder, which serves the purpose of dispersing inherent oxides of both the feedstock and the substrate. At the same time it provides sufficient pressure for Metallic bonding to occur. The process has been tested on a concept level by successfully depositing a two-layered structure of commercial purity aluminium.
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hybrid Metal Extrusion bonding hyb a new technology for solid state additive manufacturing of aluminium components
Procedia Manufacturing, 2018Co-Authors: Jorgen Blindheim, Torgeir Welo, Ulf Roar Aakenes, O Grong, Martin SteinertAbstract:Abstract This paper demonstrates a concept for a new additive manufacturing process for aluminium alloys, based on the Hybrid Metal Extrusion & Bonding (HYB) technology, along with the potential for further development of the process. The process is capable of producing near net shape structures at high deposition rates, utilizing Metallic bonding to consolidate the feedstock to the substrate in the solid-state. The aluminium feedstock wire is processed through a specially designed extruder, which serves the purpose of dispersing inherent oxides of both the feedstock and the substrate. At the same time it provides sufficient pressure for Metallic bonding to occur. The process has been tested on a concept level by successfully depositing a two-layered structure of commercial purity aluminium.