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The implementation of friction crush welding (FCW) offers a versatile application in the welding of sheet metals. Three materials (EN AW 5754H22, DC01 and Cu-DHP) were analysed by applying the method with flanged edges. The additional material required to form the weld is provided by the flanged edges of the parent sheet metal. The joint is formed by the relative motion between a rotating disc, which is applied with a crushing force, and two sheet metal parts. The fundamental process variables and the requirements of the welding preparation are shown. Bond strengths, as a percentage of the yield strength of the parent material, of around 95% (DC01) 90% (EN AW 5754H22) and 62% (Cu-DHP) are achieved. Microstructural investigations reveal that a dynamic solid-state deformation and recrystallization of the additional flanged material results in a fine grain microstructure in the weld region. Reduced metallurgical changes along with minimized distortion and residual stresses in the parent material indicate low heat input. By creating a fine grain microstructure in the welding line, the friction crush welding method reveals great potential, especially for welding steel.
Joining sheet metal can be problematic using traditional friction welding techniques. Friction crush welding (FCW) offers a high speed process which requires a simple edge preparation and can be applied to out-of-plane geometries. In this work, an implementation of FCW was employed using an additional wire to weld sheets of EN AW5754 H22, DC01, and Cu-DHP. The joint is formed by bringing together two sheet metal parts, introducing a wire into the weld zone and employing a rotating disk which is subject to an external force. The requirements of the welding preparation and the fundamental process variables are shown. Thermal measurements were taken which give evidence about the maximum temperature in the welding center and the temperature in the periphery of the sheet metals being joined. The high welding speed along with a relatively low heat input results in a minimal distortion of the sheet metal and marginal metallurgical changes in the parent material. In the steel specimens, this FCW implementation produces a fine grain microstructure, enhancing mechanical properties in the region of the weld. Aluminum and copper produced mean bond strengths of 77 and 69 pct to that of the parent material, respectively, whilst the steel demonstrated a strength of 98 pct. Using a wire offers the opportunity to use a higher-alloyed additional material and to precisely adjust the additional material volume appropriate for a given material alignment and thickness.