A4

Working Group A | Metallurgical joint

 
 
a4_spp1640

Electrochemically-assisted joining of sheet metal

Prof. Dr.-Ing. G. Grundmeier, Universität Paderborn
Prof. Dr.-Ing. W. Homberg, Universität Paderborn
Prof. Dr.-Ing. H.J. Maier, Leibniz Universität Hannover

 
 

Abstract:

Figure 1: Illustration of the ECUF process idea: Joining by incremental rolling of electrochemically treated copper surfaces
Figure 1: Illustration of the ECUF process idea: Joining by incremental rolling of electrochemically treated copper surfaces

This research project investigates the cold pressure welding of similar and dissimilar metals by incremental forming and inline electrochemical surface activation. The project intends to identify and analyse the mechanisms of cold pressure welding in order to improve current cold welding processes in terms of process flexibility and joint strength. The joining with electrochemical support (EUCF) is a new process that intends to cold pressure weld a broad range of metal pairs. Major innovations include the determined modification of the micro and macroscopic surface structure e.g. by the inline activation of metallic surfaces using electrochemical reactions (like oxide reduction and metal layer deposition). The course and result of the following pressure welding process is supported by a special tool set-up and an adapted incremental process control to ensure a sufficient bonding process with locally restricted high deformation ratios.

The pressure welding process will be realized with support of robotic actuators and an incremental process control to allow both partial and fully joining of hybrid products/assemblies made from various semi-finished parts.

 
 
Figure 2: Electrochemically treatment of copper surfaces leads to stronger cold pressure welds (Data recompiled from [Schmidt2015])
Figure 2: Electrochemically treatment of copper surfaces leads to stronger cold pressure welds (Data recompiled from [Schmidt2015])
 
 

Project Goals:

  • Development of electrochemical inline surface treatment strategies
  • Joining by forming with a new incremental rolling process
  • Overcome current limitations regarding materials and weld geometry
  • High strength cold pressure welds
  • Multi material combinations (Al-Cu, St-Al, St-St)

 
 

Publications:

2019   
  The Role of Heat-Treatments performed before and after a Cold Roll Bonding Process of Galvanized Steel Sheets Hordych, I.; Herbst, S.; Nürnberger, F.; Schmidt, H. C.; Orive, A. G.; Homberg, W.; Grundmeier, G.; Maier, H. J.
In: Proceedings of the 22nd International ESAFORM Conference on Material Forming, ESAFORM 2019, 07.05. – 10.05.2019, Vitoria-Gasteiz, Spain, 2019. (accepted)
2018   
  Influence of Heat-Pretreatments on the Microstructural and Mechanical Properties of Galfan-Coated Metal Bonds I. Hordych, H. C. Schmidt, W. Homberg, and H. J. Maier
In AIP Conference Proceedings 1960 (2018), Vol. 1960, p. 40007.
  Cold Pressure Welding Aluminium-Steel Blanks: Manufacturing Process and Electrochemical Surface Preparation H. C. Schmidt; A. G. Orive; W. Homberg; G. Grundmeier; I. Hordych; H. J. Maier
In AIP Conference Proceedings 1960 (2018), Vol. 1960, p. 50007.
2017   
  Manufacture of thin-walled clad tubes by pressure welding of roll bonded sheets H. C. Schmidt; O. Grydin; M. Stolbchenko, W. Homberg; M. Schaper
In Proceedings of the ESAFORM 2017 // Proceedings of the 20th International ESAFORM Conference on Material Forming.
ESAFORM 2017 : conference date, 26–28 April 2017 : location, Dublin, Ireland, edited by D. Brabazon, S. Naher, and I. U. Ahad (AIP Publishing, Dublin, Ireland, 2017), p. 110003.
2016   
  Elektrochemisch unterstütztes Fügen von Blechförmigen Werkstoffen durch Umformen H. C. Schmidt; C. Hoppe
iIn LH insight : Forschung im Institut für Leichtbau mit Hybridsystemen,
edited by Insitut für Leichtbau mit Hybridsystemen
(Universität Paderborn, ILH, Paderborn, 2016), pp. 22–24.
  Effect of Pre-Rolling Heat Treatments on the Bond Strength of Cladded Galvanized Steels in a Cold Roll Bonding Process Hordych, I.; Rodman, D.; Nürnberger, F.; Hoppe, C.; Schmidt H. C.; Grundmeier, G.; Homberg, W.; Maier H. J.
In: steel research international,
Version of Record online: 6 APR 2016
DOI: 10.1002/srin.201600021
  Molecular Engineering of Aluminium-Copper Interfaces for Joining by Plastic Deformation
Hoppe, C.; Ebbert, C.; Voigt, M.; Schmidt, H.C.; Rodman, D.; Homberg, W.; Maier, H.J.; Grundmeier, G.
In: Advanced Engineering Materials, TBA, 2016
  Influence of the surface and heat treatment on the bond strength of galvanised steel/aluminium composites joined by plastic deformation Hoppe, C.; Ebbert, C.; Schmidt, H.C.; Hordych, I.; Homberg, W.; Maier, H.J.; Grundmeier, G.
In: Advanced Materials Engineering, TBA, 2016
  Cold pressure welding by incremental rolling: deformation zone analysis Schmidt, H. C.; Homberg, W.; Hoppe, C.; Grundmeier, G.; Hordych, I.; Maier, H. J.:
In: AIP Conference Proceedings, TBA, 2016
2015   
  Investigation of cold pressure welding: cohesion coefficient of copper Schmidt, H. C.; Rodman, D.; Ebbert, C.; Homberg, W.; Maier, H. J.; Grundmeier, G.
In: Key Engineering Materials 651–653, 1421–1426, 2015
2014   
  Joining with electrochemical support (ECUF): Cold pressure welding of copper Ebbert, C.; Schmidt, H. C.; Rodman, D.; Nürnberger, F.; Homberg, W.; Maier, H. J.; Grundmeier, G.
In: Journal of Materials Processing Technology 214(10), 2179–2187, 2014
  Joining with electrochemical support: cold pressure welding of copper – weld formation and characterization Schmidt, H. C.; Rodman, D.; Grydin, O.; Ebbert, C.; Homberg, W.; Maier, H. J. & Grundmeier, G.
In: Advanced Materials Research 966-967, 453-460, 2014
2013   
  Partial joining of blanks with electrochemical support (ECUF) Schmidt, H. C.; Homberg, W.; Grundmeier, G.; Maier, H. J.
In: Key Engineering Materials 554–-557, 1091–1095, 2013
  Hybrid – Neue Werkstoffe und Prozesse für den Leichtbau Schmidt, H. C.; Homberg, W.
In: Alexander Brosius, ed., '20. Sächsische Fachtagung Umformtechnik – Tagungsband', pp. 25–32, 2013
2012   
  New Materials – Driver for Innovative Production Processes W. Homberg; H. C. Schmidt; A. Struwe; O. Akst
In: Proceedings of the IDDRG Conference 2012.
Lightweighting: Possibilities & Challenges, edited by A. Tewari, K. Narasimhan, and P. P. Date (Mumbai, Indien, 2012), pp. 34–39.
 

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