Fundamentals of Extrusion-Based Aluminum Welding and Additive Manufacturing explores the potential of extrusion-based aluminum welding and additive manufacturing (AM) in an industrial context, in light of how age-hardened Al–Mg–Si alloys respond to conventional fusion welding and friction stir welding (FSW). The primary focus is on the hybrid metal extrusion and bonding (HYB) process, which employs continuous rotary extrusion to achieve metallurgical bonding between different metals and alloys in the solid state with the addition of aluminum filler metal. Thanks to its versatility and flexibility, the HYB process can be applied to a wide range of operations, including butt, fillet, and lap welding, as well as plate surfacing, multimaterial welding, and AM.
The chapters are organized in a manner that makes the HYB technology easily accessible to professionals in both academia and industry who are already familiar with FSW. Detailed information is provided on the design and operation of the PinPoint extruder, representing the core outcome of the HYB development project. To help readers with diverse backgrounds understand and engage with the topics covered, the learning process is enhanced by integrating relevant physically based models into specially designed case studies throughout the text.
1. Title of Book - p. i 2. Cover Image - p. i 3. Title Page - p. ii 4. Table of Contents - p. iii 5. Copyright - p. iv 6. Dedication - p. v 7. About the author - p. xiii 8. Preface - p. xv 9. Chapter 1 Metallurgical challenges in conventional aluminum welding and additive manufacturing - p. 1 10. Chapter 2 Potential extrusion processes for solid-state aluminum welding and additive manufacturing - p. 99 11. Chapter 3 The engineering design process behind the HYB PinPoint extruder innovation - p. 131 12. Chapter 4 Fundamentals of the hybrid metal extrusion and bonding (HYB) process - p. 183 13. Chapter 5 The versatility of the HYB process and its competitiveness against GMAW, LBW, and FSW - p. 229 14. Chapter 6 Guidelines for designing an industrial version of the HYB PinPoint pilot extruder - p. 283 15. Chapter 7 Manufacturing of customized aluminum filler wires for the HYB process - p. 319 16. Chapter 8 Exercises with solutions - p. 345 17. Nomenclature - p. 371 18. Author Index - p. 383 19. Subject Index - p. 387
Fundamentals of Extrusion-Based Aluminum Welding and Additive Manufacturing explores the potential of extrusion-based aluminum welding and additive manufacturing (AM) in an industrial context, in light of how age-hardened Al–Mg–Si alloys respond to conventional fusion welding and friction stir welding (FSW). The primary focus is on the hybrid metal extrusion and bonding (HYB) process, which employs continuous rotary extrusion to achieve metallurgical bonding between different metals and alloys in the solid state with the addition of aluminum filler metal. Thanks to its versatility and flexibility, the HYB process can be applied to a wide range of operations, including butt, fillet, and lap welding, as well as plate surfacing, multimaterial welding, and AM.
The chapters are organized in a manner that makes the HYB technology easily accessible to professionals in both academia and industry who are already familiar with FSW. Detailed information is provided on the design and operation of the PinPoint extruder, representing the core outcome of the HYB development project. To help readers with diverse backgrounds understand and engage with the topics covered, the learning process is enhanced by integrating relevant physically based models into specially designed case studies throughout the text.
1. Title of Book - p. i 2. Cover Image - p. i 3. Title Page - p. ii 4. Table of Contents - p. iii 5. Copyright - p. iv 6. Dedication - p. v 7. About the author - p. xiii 8. Preface - p. xv 9. Chapter 1 Metallurgical challenges in conventional aluminum welding and additive manufacturing - p. 1 10. Chapter 2 Potential extrusion processes for solid-state aluminum welding and additive manufacturing - p. 99 11. Chapter 3 The engineering design process behind the HYB PinPoint extruder innovation - p. 131 12. Chapter 4 Fundamentals of the hybrid metal extrusion and bonding (HYB) process - p. 183 13. Chapter 5 The versatility of the HYB process and its competitiveness against GMAW, LBW, and FSW - p. 229 14. Chapter 6 Guidelines for designing an industrial version of the HYB PinPoint pilot extruder - p. 283 15. Chapter 7 Manufacturing of customized aluminum filler wires for the HYB process - p. 319 16. Chapter 8 Exercises with solutions - p. 345 17. Nomenclature - p. 371 18. Author Index - p. 383 19. Subject Index - p. 387
