Kraus Stefan Oliver, Bruder Johannes, Schuller Florian, Groche Peter
Institute for Production Engineering and Forming Machines, TU Darmstadt, D-64287 Darmstadt, Germany.
Materials (Basel). 2025 Jun 21;18(13):2944. doi: 10.3390/ma18132944.
Collision welding represents a promising solid-state joining technique for combining both similar and dissimilar metals without the thermal degradation of mechanical properties typically associated with fusion-based methods. This makes it particularly attractive for lightweight structural applications. In the context of collision welding, it is typically assumed that ideally smooth and defect-free surface conditions exist prior to welding. However, this does not consistently reflect industrial realities, where surface imperfections such as scratches are often unavoidable. Despite this, the influence of such surface irregularities on weld integrity and quality has not been comprehensively investigated to date. In this study, collision welding is applied to the material combination of AA6110A-T6 and AA6060-T6. Initially, the process window for this material combination is determined by systematically varying the collision velocity and collision angle-the two primary process parameters-using a special model test rig. Subsequently, the effect of surface imperfections in the form of defined scratch geometries on the resulting weld quality is investigated. In addition to evaluating the welding ratio and tensile shear strength, weld quality is assessed through scanning electron microscopy (SEM) of the bonding interface and high-speed imaging of jet formation during the collision process.
碰撞焊接是一种很有前景的固态连接技术，可用于连接同种和异种金属，且不会出现通常与熔焊方法相关的机械性能热降解问题。这使得它在轻质结构应用中特别有吸引力。在碰撞焊接的背景下，通常假定在焊接前存在理想的光滑且无缺陷的表面条件。然而，这并不能始终反映工业实际情况，在工业中，诸如划痕等表面缺陷往往不可避免。尽管如此，迄今为止，此类表面不规则性对焊接完整性和质量的影响尚未得到全面研究。在本研究中，将碰撞焊接应用于AA6110A-T6和AA6060-T6的材料组合。首先，使用特殊的模型试验台，通过系统地改变碰撞速度和碰撞角度这两个主要工艺参数，确定该材料组合的工艺窗口。随后，研究了以特定划痕几何形状形式存在的表面缺陷对所得焊接质量的影响。除了评估焊接率和拉伸剪切强度外，还通过对结合界面的扫描电子显微镜（SEM）和碰撞过程中射流形成的高速成像来评估焊接质量。
