IWT Bremen (Stiftung Institut für Werkstofftechnik)
The efficient determination of the time-temperature-property relations of thermally joined aluminum alloy components for numerical stress analyses.
The thermal joining of aluminum alloys usually results in the degradation of local material properties. A reduction of strength related properties within the so-called "heat-affected zone" (HAZ) by a short-term topically focused transmission of heat is especially undesirable. The precise determination of these mechanical properties is currently still only possible with a great amount of time and at a great cost, which is largely dependent on the outlay for experimentally determining the material property values. These efforts usually make small and mid-sized enterprises refrain from attempting to manufacture thermally joined structural components. The chance that suppliers or engineering services, e.g. for the automotive industry, can open up new markets is therefore rare. This could however be made possible by the knowledge gained through a simulation that allows for definite statements about the formability of joined aluminum alloy components. The advantages gained from this knowledge and the great potential for saving developments time and costs, means that a simulation-based solution would encourage the development and implementation of new and improved lightweight manufacturing approaches.
The technical goal of this project is the efficient determination of initial data for the simulation and the validation of an approach based on examples from practice, as follows:
A method for the efficient determination of material property values that is applicable to the most important processes of thermally joining aluminum alloys and that forms the base of a material model that is applicable to all aluminum alloys.
A material model for the sufficient and precise calculation of mechanical properties and material states in the HAZ and the melting zone that is to be implemented in a thermo-mechanical welding simulation by adjusting Simufact.welding.
Expanding Simufact.welding so that stress analyses based on the results of the welding simulation can be performed and evaluated with a simple user interface.
Articles on the project
Method for efficient determination of material properties for modelling aluminium welding processes
The trend in the automotive and aircraft industry is moving towards customized designs by using compound structures, which provide an enlarged potential for weight and cost savings. Particularly, thermal joined lightweight structures made of aluminium alloys are characterized by moderate material and processing costs.
Authors: B. Striewe, J. Seiderer, A. von Hehl, A. Repenning, P. Khazan and H. Schafstall
Article published in: Materials Science & Engineering Technology, Vol. 47 - No. 11 - November 2016, Wiley-VCH