Model Test Rig for Collision Welding

Model test rig for collision welding to investigate the fundamental mechanisms of collision welding with high repeatability.

Figure 1: Left: test rig (without housing), right: close-up of the specimens mounted on the rotors

By a defined impact of two joining partners a material closed joint can be realized even between different materials that cannot be welded thermally. However, the industrial used processes are hardly observable, whereby the joining mechanisms are still not fully understood. While the observability in explosion welding is limited due to the explosives, the joining process in electromagnetic pulse welding is strongly transient as well.

The model test rig experiment has therefore been developed in order to be able to investigate the fundamental mechanisms of collision welding with high repeatability. Therefore an adjustable variation of individual process parameters with otherwise constant test conditions and good process observability are in the main focus.

Figure 2: Series of high speed images of a collision welding process

During the process, two samples collide mechanically accelerated by two revolving rotors, which initiates the welding process. The processes in the collision region are documented by means of high-speed images of an image intensifier camera. A long distance microscope system provides a high local resolution of the area observed, while a pulsed diode laser also ensures adequate illumination and allows imaging under incident as well as transmitted light.

  • Two controlled synchronous motors
  • Drive power: 2 x 12 kW
  • Impact velocity: up to 260 m/s
  • Angular deviation: mx. 0,1°