Fundamentals of Extrusion-based Aluminum Welding and Additive Manufacturing : A Step-by-step Guide

Fundamentals of Extrusion-Based Aluminum Welding and Additive Manufacturing explores the potential of extrusion-based aluminum welding and additive manufacturing (AM) in an industrial context, in light of how age-hardened Al–Mg–Si alloys respond to conventional fusion welding and friction stir welding (FSW). The primary focus is on the hybrid metal extrusion and bonding (HYB) process, which employs continuous rotary extrusion to achieve metallurgical bonding between different metals and alloys in the solid state with the addition of aluminum filler metal. Thanks to its versatility and flexibility, the HYB process can be applied to a wide range of operations, including butt, fillet, and lap welding, as well as plate surfacing, multimaterial welding, and AM.

The chapters are organized in a manner that makes the HYB technology easily accessible to professionals in both academia and industry who are already familiar with FSW. Detailed information is provided on the design and operation of the PinPoint extruder, representing the core outcome of the HYB development project. To help readers with diverse backgrounds understand and engage with the topics covered, the learning process is enhanced by integrating relevant physically based models into specially designed case studies throughout the text.

• Explains the response of Al–Mg–Si extrusions to welding in terms of their physical metallurgy and manufacturing route
• Reviews recent advances in extrusion-based solid-state welding and additive manufacturing (AM) with filler metal additions, focusing on the HYB process and its competitiveness compared with other methods
• Discusses the conditions required for achieving solid-state bonding in aluminum and multimaterial welds, emphasizing how key mechanical properties can be optimized using physically based models for simulating the thermal, microstructural, and strength evolution fields during welding and AM

Øystein Grong (born in 1956) received his PhD from the Norwegian University of Science and Technology (NTNU) in 1983. He has served as a Visiting Research Professor at the Colorado School of Mines in Golden, Colorado, and at the National Institute of Standards and Technology in Boulder, Colorado (USA). In 1987, he was appointed Professor of Metallurgy at NTNU by the King of Norway and the Prime Minister.

Professor Grong has broad interests and extensive research experience in materials science in general, and in microstructural modelling in particular. His work emphasizes industrial manufacturing methods such as welding, brazing, casting, extrusion and heat treatment of metals and alloys. A significant portion of his research is related to innovation and the development of new processes and products.

During his tenure at NTNU, Professor Grong has supervised numerous MSc and PhD students and authored more than 300 publications, including 110 major scientific papers in peer-reviewed international journals. He is also the author of the well-regarded international textbook Metallurgical Modelling of Welding, which was formerly ranked among the top ten best-selling books from the Institute of Materials in London. In addition, he has contributed to 10 patents and received four international awards and one prestigious national award for his scientific contributions.

Professor Grong is currently self-employed through his own consulting company and is fully engaged in the development of the hybrid metal extrusion & bonding (HYB) process, in collaboration with industry partners and colleagues at the Department of Mechanical and Industrial Engineering, NTNU.