A Semi-Analytical Model for the Heat Generation during Hybrid Metal Extrusion and Bonding (HYB)

• Main Authors: Francesco Leoni, Øystein Grong, Paolo Ferro, Filippo Berto
• Format: Article
• Language: English
• Published: MDPI AG 2021-12-01
• Series: Materials
• Subjects: aluminium butt welding; hybrid metal extrusion and bonding; frictional heating; heat flow modelling; thermal efficiency factor
• Online Access: https://www.mdpi.com/1996-1944/14/1/170

Hybrid Metal Extrusion and Bonding (HYB) is a novel solid-state welding method for metals and alloys that utilises continuous extrusion as a technique to enable aluminium filler metal additions. In the present study, a new semi-analytical model for the heat generation during aluminium butt welding is presented. As a starting point, the classical Rosenthal thin plate solution for the pseudo-steady-state temperature distribution around a fully penetrating line source is invoked. Then, the associated heat generation is calculated by considering the individual contributions from the tip of the rotating pin, the pin shoulder, and the filler metal additions on the net power input. In a calibrated form, the model yields thermal efficiency factors that are in close agreement with those obtained from more sophisticated finite element analyses but with considerably less computational effort.