Finite element modelling of the filler wire feeding in the hybrid metal extrusion & bonding (HYB) process

HYB is a new solid-state joining method for metals and alloys that utilises continuous extrusion as a technique to enable aluminium filler metal additions. In the present paper a finite element (FE) model for the filler wire feeding inside the HYB PinPoint extruder has been developed and implemented within the commercial software package Deform 3D ™. Based on a comparison with experimental data for the extruder housing temperature, the drive spindle torque and the wire feed rate, it is concluded that the FE model is sufficiently relevant and comprehensive to be used in future developments of the HYB process. In addition to improved wire feeding control, a model-based approach will make it possible to reduce the engineering time and costs involved in case a modification of the design is needed to optimise the extruder performance in a real joining situation.