Preliminary Benchmarking of the HYB (Hybrid Metal Extrusion & Bonding) Process for Butt Welding of AA6082-T6 Plates Against FSW and GMAW

The patented Hybrid Metal Extrusion & Bonding (HYB) process enables joining of aluminium components with filler metal addition in the solid state. The mechanical properties of a 4 mm AA6082-T6 butt joint made using this technique have been determined. The experimental programme included transverse hardness testing, tensile testing and Charpy V-notch testing, sampling different regions of the weldment. In addition, both optical microstructure analysis of the weld and scanning electron microscope examination of selected fracture surfaces have been carried out. The resulting mechanical integrity of the joint is then compared with that typically achieved using conventional GMAW and FSW. The preliminary benchmarking of the HYB process shows that the mechanical properties of the joint, i.e. strength, ductility, impact toughness and load-bearing capacity, are slightly better than the values reported for a comparable GMA weld. Still, they do not fully match those of a sound FS weld. Therefore, there is a potential for further optimization of the HYB process in order to bring the method to the forefront of aluminium welding technology. This work is now in progress