Joining of blanks with electrochemical support (ECUF)

本研究项目采用增量成形和在线电化学表面活化的方法，对异种金属和异种金属的冷压焊进行了研究。该项目旨在确定和分析冷压焊接的机理，以便在工艺灵活性和接头强度方面改进目前的冷焊工艺。采用电化学支撑(EUCF)连接是一种新工艺，适用于多种金属对的冷压焊接。主要创新包括对微观和宏观表面结构的特定修改，例如通过电化学反应(包括氧化物还原和金属层沉积)在线激活金属和聚合物表面。后续压力焊接工艺的过程和结果由特殊的工具设置和适当的增量式工艺控制来支持，以确保充分的结合工艺，并具有局部限制的高变形率。压力焊接过程将由机器人执行器和增量式过程控制来实现，以允许由各种半成品组成的混合产品/组件的部分和全部连接。该提案旨在更深入地了解电化学在线活化和渐进成形所导致的机械连接所涉及的微观和宏观过程。提出了跨学科的基础研究，以解决成形、电化学和材料科学之间的相互作用，并达到预期的结果。为随后的工业应用创造了技术基础，通过对板材外壳进行电化学支撑成形来进行连接。这一社区应用程序还促进了每个参与小组在其研究领域内获得普遍的知识。因此，每个单独的工艺步骤，如机械或化学准备、半成品的处理和连接过程本身，都将进行详细的研究。将进行金相分析，这是从牢固的结合、应用性能以及强度和耐久性方面仔细描述所得到的接头所必需的。

This research project investigates the cold pressure welding of similar and dissimilar metals by incremental forming and inline electrochemical surface activation. The project intends to identify and analyse the mechanisms of cold pressure welding in order to improve current cold welding processes in terms of process flexibility and joint strength. Joining with electrochemical support (EUCF) is a new process intended for the cold pressure welding of a broad range of metal pairs. Major innovations include the specified modification of the micro- and macroscopic surface structure, such as through inline activation of metallic and polymeric surfaces by means of electrochemical reactions (including oxide reduction and metal layer deposition). The course and result of the subsequent pressure welding pro-cess is supported by a special tool setup and an adapted incremental process control to ensure a sufficient bonding process, with locally restricted high deformation ratios. The pressure welding process will be realized by robotic actuators and an incremental process control to allow both partial and full joining of hybrid products/assemblies made up of various semi-finished parts. The proposal aims to achieve a deeper understanding of the micro- and macroscopic processes involved in electrochemical inline activation and the mechanical joint induced by incremental forming. Interdisciplinary basic research is pro-posed to address the interacting aspects of forming, electrochemistry and material science and attain the aspired result. A technological basis is to be created for the subsequent industrial use of joining by forming with electrochemical support for the case of sheet metal. This community application also promotes a universal knowledge gain for each of the participating groups within their field of research. Hence, each individual process step, such as mechanical or chemical preparation, the handling of the semi-finished parts and the joining process proper will be investigated in detail. Metallographic analysis will be performed, and this is necessary for carefully characterizing the resulting joint in terms of solid bonding, application performance and also strength and durability.