Fundamentals of Extrusion-Based Aluminum Welding and Additive Manufacturing

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. - Explains the response of Al–Mg–Si extrusions to welding in terms of their physical metallurgy and manufacturing route - Reviews recent advances in extrusion-based solid-state welding and additive manufacturing (AM) with filler metal additions, focusing on the HYB process and its competitiveness compared with other methods - Discusses the conditions required for achieving solid-state bonding in aluminum and multimaterial welds, emphasizing how key mechanical properties can be optimized using physically based models for simulating the thermal, microstructural, and strength evolution fields during welding and AM