Fundamentals of the Hybrid Metal Extrusion and Bonding Process

Fundamentals of the Hybrid Metal Extrusion and Bonding Process details this novel solid-state welding method (HYB) that utilizes continuous rotary extrusion as a technique to enable metallurgical bonding between different metals and alloys by aluminum filler metal additions. Due to its versatility and flexibility the process can be applied to solid-state plate surfacing and additive manufacturing, each of which is also outlined in the book. The book starts with an overview of the current challenges involved with welding aluminum alloys, including those associated with conventional fusion welding and friction stir welding of age-hardening Al-Mg-Si alloys. Readers will gain insight into how the properties achieved depend on both the chemical composition and the applied thermomechanical processing and heat treatment schedules. Simple analytical models are presented for rapid assessment of the response of the alloys to welding, and sections on diffusion and intermetallic compound formation during multimaterial joining and modeling and simulation of the thermal, microstructural, and strength evolution fields during welding are also discussed. From there, the book then introduces the HYB method and how it can help overcome those commonly-encountered welding challenges. Following chapters outline the design of the extruder tool, explain how to tailor the process, how to select the tool material and coating, and how to design the cooling, wire feeding, and control systems. The book concludes with a chapter providing guidance on optimization and upscaling, demonstrating the competitive advantages HYB has over conventional welding methods such as gas metal arc welding, laser beam welding, and friction stir welding.