Preliminary Finite Element assessment of residual stresses in dissimilar AA6082-S355 butt welded joints produced with the Hybrid Metal Extrusion and Bonding (HYB) technique

Abstract Hybrid Metal Extrusion & Bonding (HYB) is a new solid-state joining method for metals and alloys that utilizes continuous extrusion as a technique to enable aluminum filler metal additions. Previous works showed that this method is well suitable for joining dissimilar metals such as steel and aluminum. In the present paper a Finite Element model for the thermal residual stresses were implemented employing the FE code WELDSIM. As a starting point, the results of a semi-analytical heat generation model previously implemented for HYB process of aluminum butt welds were used to estimate the net power input as a sum of contributions that are dependent on the welding parameters i.e. the welding speed, the rotational speed and the material properties. Subsequently, the thermal stresses occurring in the material and finally the residual stresses were determined. In the present work, predictions of the FE model for different sets of welding parameters are presented and discussed.