Robot-assisted EMPT sheet welding of lightweight hybrid materials

Transcription

1 Robot-assisted EMPT sheet welding of lightweight hybrid materials Stephan Kallee, Dr. Ralph Schäfer, Dr. Pablo Pasquale Wir fügen anders... We join differently...

2 EMPT Sheet Welding Characteristics 20µs processing time No Heat Affected Zone (HAZ) No thermal distortion Atomic bonding (solid phase weld) No metallurgic changes in the weld area No inter-metallic phases Contact less No shielding gases

3 Electromagnetic Pulse Technology (EMPT)

4

5 EMPT Sheet Welding: Eddy Currents

6 EMPT Sheet Welding: Principle Oxide layer

7 EMPT Sheet Welding: Micro Section 200µm Flyer Target

8 EMPT Sheet Welding Dissimilar material combinations EMPT welding of hat sections Metallography: No heat affected zone 280 µm aluminium, 2mm copper

9 EMPT Sheet Welding: Aluminium onto Steel Steel Aluminium

10 EMPT Sheet Welding Three layers 280µm Al, 200 µm Cu EMPT welding of foil stacks: 10 x 250 µm Cu Face contact Cu-Al

11 Robot-assisted EMPT Sheet Welding: Space Frame Steel / Aluminium welded Steel Aluminium

12 Robot-assisted EMPT Sheet Welding Videos: Frame: Battery:

13 EMPT Sheet Welding

14 EMPT Sheet Welding Impact Aufschlag Applied work Work, Energy Kinetic energy Deform. energy Time [µs]

15 EMPT Sheet Welding: Failure Modes Failure of the softer workpiece near the welding zone. Reasons: Notch effect by change in stress state dimensionality Geometric notch

16 EMPT Sheet Welding: Improved Process Workaround agains failure by geometric notch: Change in material flow during welding

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18 EMPT Sheet Welding: Improved Process Advantages of improved process: No crevice between welded sheets after EMPT welding Less surface deformations after EMPT process No spacer essential within EMPT process: easy to position Minimized geometric notch Improved weld quality Pre-shape can be manufactured within the deep drawing process Weld Weld

19 EMPT Sheet Welding: Weld Properties After welding the materials cannot be separated Aluminium The mechanical strength is at least high as that of the weaker material when welding dissimilar materials The strength of the joint is at least as high as the parent material properties when welding similar materials Steel

20 EMPT Sheet Welding: Weld Properties Strength AA 5754 Stress [N] EMPT Weld Strain [%]

21 EMPT Sheet Welding: Material Properties Increasing Discharging Energy

22 EMPT Sheet Welding: Material Properties Aluminium Copper (nickel coated) F=4720 N Aluminium parent material F=4520 N Weld

23 EMPT Sheet Welding: Material Properties Significant plastic deformation close to the joint line Characteristic wave pattern Absence of brittle intermetallic phases No heat affected zones No grain growth, no recrystallisation and no growth of precipitation zones

24 EMPT Sheet Welding: Material Properties Failure load, kn Failure load, kn Displacement, mm Displacement, mm Al-Al Al-Steel

25 EMPT Sheet Welding: Material Properties Steel No resolidification No intermetallic phases Aluminium BSE SE High Resolution

26 EMPT Sheet Welding: Material Properties Collission angle β Weld zone Low impact speed Jet High impact speed No jet The collision angle β and impact speed at the contact point are the key parameters for good welds Both parameters are closely interlinked The generation of a jet is a necessity for welding Impact speed v

27 EMPT- Machine Systems (Pulse Generators and Coils)

28 EMPT Systems PSxx BlueWave

29 Modular EMPT BlueWave System PS96-16 for Sapa

30 EMPT System PSxx Series at BOSCH Bamberg

31 EMPT Systems PSxx Series

32 EMPT Systems PSxx Series

33 Bosch Bamberg PS48-10

34 Modular EMPT BlueWave System PS for IWU

35 Modular EMPT BlueWave System PS at IWU

36 PSTproducts GmbH: Locations Head Quarters Alzenau Sales Office Austria Sales Office Shanghai Sales Office USA PSTproducts GmbH Junkersstrasse Alzenau T: +49 (0) F: +49 (0) Karpfenweg Seekirchen AUSTRIA T: +43 (6212) M: +43 (650) Shanghai Welding & Cutting Engineering Co., Ltd. No. 38, 1398 Lane, Zhen Chen Rd. Tai Ding Industry Zone, Shanghai China Michigan Office Mr. Robert Walther 930 East Drayton Ferndale MI USA T: Saled Office South Sales Office Switzerland Verkaufsbürro Taiwan Sales Office India Bock Handelsvertretung GmbH Wiesentalstr Oberndorf a. N. T.: +49 (0) Listec Schweisstechnik Dietrichstrasse 1 Ch 9424 Rheineck T: +41(0) NAN KING Enterprise Co.,Ltd. Attn. Jins Chang No.11 Alley 77 Lane 133, Chung Hua East Road Sec.2, Tainan, Taiwan R.O.C. Tel: Proteck Machinery Pvt Ltd Chennai India T: or 16 T: Sales Office Nord Sales Office Scweden Sales Office South Korea Sales Office Japan Bock Handelsvertretung Nord GmbH Seidenweberstr. 37b Krefeld Tel.: / Sales Office East Mr. Kaj Riesterer Stormbyvägen Spånga T: T: Sales Office Asiea Woorim Korea Co., Ltd Maha-Ri, Bongdam-eup Haw Sung-City, Kyungki-Do, South Korea T: Sales Office Moskow Correns Corporation Ark Yagi Hills 3rd floor, 8-7, Roppongi 1-Chome, Minato-Ku Tokyo T: 81 (0) SCAMA GmbH Gartenstraße Königsbrück T: T: Harald Kuchenbäcker Birkenweg 10a Pfronten Tel: KONTUR group of companies Bolshaya Novodmitrovskaya str, 14, bld 2 office 225, Moscow Russia

37 Conclusions Benefits - Free material selection - No heat affected zone - Proven reliability - Ease of automation - Parameter Monitoring - Exclusivity - Competitive advantage - Significant cost reduction Why PSTproducts? - Market leader for industrial systems - State of the Art systems with very durable components - Several joints with one pulse - Experience with customer specific solutions

38 Second EMPT Conference and Users Meeting