Automation of Vaporized Foil Activation Welding, and Metal Adhesives

In automating Vaporized Foil Activation Welding (VFAW) numerous manufacturing opportunities are made available for automotive, aeronautical, and medical fields. Electronic detonation vaporizes an aluminum foil, resulting in a plasma explosion which forces the metal sheets to collide creating an impulse weld. It is effective in joining a wide variety of dissimilar metals without melting the samples. Resulting in a weld which is stronger than the base material. However, human error and time-intensive nature created inconsistent results within material data. In order to remedy this, the process was automated. 3D modeling software, CAM, CAD were implemented in order to design, program, fabricate, and build the machine.  This machine dispensed adhesives, aligned and conveyed the metal coupons to then welded them. Results were then compiled by mechanical and laser testing, ultimately displaying significant evidence that the automation of VFAW was successful and efficient. Work was completed at the Ohio State University in the Materials Science Engineering Department, under Dr. Glenn Daehn in the Impulse Manufacturing Laboratory with Graduate Student Brian Ufferman. 

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