SBIR PhaseI: High Velocity Impact Bonding of Dissimilar Metals by Energy Released in Chemical Production of Hydrogen

该小型企业创新研究（SBIR）第一阶段项目旨在通过铝/水反应化学产生氢能来推进异种金属/冲击焊接行业的制造工艺。 理想地，约100 kpsi-200 kpsi形式的能量可以是小型高速冲击结合机的动力源，以摩擦结合不同的金属。 目前的冲击焊接方法，如爆炸焊接，还没有产生用于焊接近净形零件的机器，而是一种制备待切割成所需较小零件的大型原材料的工艺。 与爆炸物有关的缺点包括安全问题、交货时间长、成本高、材料浪费和依赖进口。 高速冲击焊接机可以彻底改变较小的离散部件的制造，为设计工程师开辟新的途径。 将进行实验以建立冲击诱导互锁微键合的理想条件，例如，铜和不锈钢的区别 该项目的可变测试参数包括：（a）飞片速度（隐含地由氢压力决定），（B）飞片与砧座或基底材料之间的冲击角度，（c）飞片与砧座材料之间的间隔距离，以及（d）表面形貌。 研究结果将为异种金属的波形接头形态提供优化条件。该项目更广泛的影响/商业潜力归因于新能源的利用，该能源将改变某些制造工艺的供电方式。铝/水反应的进步，以取代爆炸物或复杂的压力，热量或电源的电，摩擦，热或冲击焊接方法制造不同的金属部件将证明有许多好处，通过开发一个安全，用户友好和环境友好的焊接机。此外，使用高压流体的锻造和液压成形等其他工艺的冲击载荷也将利用这些优点。这种机器的引入将提供多功能的装配线制造能力，其优点包括：（a）大量节省成本，（B）激励小型美国制造公司在美国国内生产离散部件，(c)潜在的定制部件的新设计，否则是不可行的，（d）低技能操作的小型设施，消除了长的交货时间，和（e）其他制造工艺的潜力，可以使用这个平台技术。 异种/双金属零件在化学、汽车、飞机、船舶和核工业中需求量很大，因为它们具有高导电性和耐电偶腐蚀性，并且一个零件中包含良好的机械性能。

This Small Business Innovation Research (SBIR) Phase I project seeks to advance manufacturing processes in the dissimilar metal/impact welding industries via an aluminum/water reaction that chemically produces hydrogen energy. Ideally, the energy in the form of about 100 kpsi-200 kpsi, could be the source of power for a small high-velocity impact bonding machine to metallurgically bond dissimilar metals. Current impact bonding methods such as explosive welding have not led to machines for bonding near-net-shaped parts, but rather a process of preparing large raw materials to be cut into the desired smaller parts. Disadvantages associated with explosives include safety issues, long lead-times, high costs, material waste, and reliance on imports. A high-velocity impact bonding machine could revolutionize the manufacturing of smaller, discrete parts opening new avenues for design engineers. Experiments will be conducted to establish the ideal conditions for impact induced interlocking micro-bonds, e.g., between Copper and Stainless Steel. The variable test parameters of this project include: (a) flyer velocity (implicitly determined by hydrogen pressure), (b) impact angle between the flyer plate and the anvil or base material, (c) standoff distance between flyer and anvil material, and (d) surface topography. The results will lead to optimized conditions for wavy-joint morphology of dissimilar metalsThe broader impact/commercial potential of this project is attributed to the utilization of a new energy source that will transform how some manufacturing processes are powered. The advancement of an aluminum/water reaction to replace explosives or complex pressure, heat or electrical sources for electrical, friction, heat or impact bonding methods of manufacturing dissimilar metal components will prove to have many benefits by developing a safe, user-friendly and environmentally-friendly bonding machine. Additionally, impact loading for other processes such as forging and hydroforming that use high pressure fluid will capitalize on these benefits as well. The introduction of this machinery will provide a versatile assembly-line manufacturing capability with advantages to include: (a) substantial cost savings, (b) motivating small U.S. manufacturing companies to produce discrete parts within the U.S., (c) potential for new designs of customized parts otherwise infeasible, (d) a low skilled operation for small facilities eliminating long lead-times, and (e) the potential for other manufacturing processes that could use this platform technology. Dissimilar/bi-metallic parts are in high demand in the chemical, automotive, aircraft, marine, and nuclear industries due to their high conductivity and galvanic corrosion resistance and favorable mechanical properties contained in one part.