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Investigation of the local suitability for welding of aluminium die-cast components
  • Bachelor and Master Thesis
    • Battery research: Selective laser sintering for use in future batteries
    • Evaluation of the influence of particle contamination depending on the separator and compression using the Hi-Pot Test
    • Contacting of metal-polymer current collectors for use in cylindrical cells: Concept development and validation
    • Optimization of a bending test for the mechanical characterization of battery electrodes
    • Influence of cutting process and free cut edge geometry on the Al-5083 fatigue strength
    • Design and testing of a device and method for the in-situ calibration of force sensors in the die casting process
    • Laser beam assembly of lithium metal anodes
    • Laser pretreatment of die-cast aluminium for in-mold assembly with plastic
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    • Remelting effect on temperature field, residual stress, and distortion in WAAM components
    • Residual stress variations during fabrication
    • Conversion and test of a heating system
    • Investigation of the local suitability for adhesive bonding of aluminium die-cast components
    • Investigation of the local suitability for welding of aluminium die-cast components
    • Influence of thermal cutting processes on the quality of the cut edges
    • Toughness of high strength welded steels

Investigation of the local suitability for welding of aluminium die-cast components

Background

Die casting is a common industrial process for the production of complexly shaped products made of light metal alloys. However, the welding of cast structures is fraught with some challenges such as hydrogen-induced, metallurgical pore formation and the irregular occurrence of surface pores and molten pool ejections. The development of these weld seam imperfections is strongly dependent on the varying material quality and influencing factors, such as hydrogen content, release agent occupancy, mold filling and venting of the die-casting mold. As a result of the imperfections that occur during the welding of aluminium die-casting, high scrap rates and high costs for necessary rework are incurred. As a result, the ecological footprint, the cost-effectiveness and the quality of the assemblies deteriorate.

Task

The aim of this thesis is to investigate the influence of casting process parameters on the local suitability for welding of aluminum die-cast components. For this purpose, a literature search on the basics of welding aluminium die casting must first be carried out. Subsequently, welding tests are to be carried out and the seams are to be examined for internal and external imperfections by means of visual inspection and computed tomography. The results of these investigations are to be correlated with the varied casting process parameters.

The picture shows an aluminium die-cast plate with 7 horizontal weld seams. The weld seams become cleaner and more even with increasing distance from the lower edge of the plate.
Varying weld seam quality depending on the position on a aluminium high pressure die cast component 

In the context of a student thesis the following fields of activity arise:

  • Literature review on the causes, effects and classification of weld seam imperfections and on the production of die-cast components suitable for welding
  • Execution of welding tests on die-cast components of different quality
  • Examination of internal and external weld seam imperfections by means of visual inspection and computed tomography
  • Data and correlation analysis of weld results and parameters varied during casting

amount of work

The scope of the work is scalable and therefore allows for student and master thesis. For a detailed task description, please contact the supervising research assistant. The time for familiarization is given under supervision.

Requirements

  • Independent, structured way of working
  • Interest in scientific work
  • Known requirements of the faculty for the submission of student papers

Start

as of now

Sebastian Krischke, M. Sc.
+ 49 531 391 95526
s.krischke(at)tu-braunschweig.de
Sebastian Krischke
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