Impact Welding of Aluminum Alloys 6061 and 5052 by Vaporizing Foil Actuators: Heat-Affected Zone Size and Peel Strength

Abstract

Joining aluminum alloy sheets is increasingly important in manufacturing. Traditional welding techniques create a heat-affected zone (HAZ) around the joint; however, solid-state joining methods such as impact welding produce joints without significant heat. Here, electrically vaporized foil actuators (VFA) provided the high-pressure pulses needed for impact welding. 0.96 mm thick AA6061-T6 and 0.76 mm thick AA5052 were joined in lap and spotlike configurations, at a variety of impact velocities. The welds failed in coach-peel outside the joint interface. The 5052 hardened within 100 μm of the interface. The 6061-T6 may have softened slightly within 50 μm of the interface.