Fundamentals of the Hybrid Metal Extrusion and Bonding Process
- 1st Edition - March 1, 2026
- Author: Øystein Grong
- Language: English
- Paperback ISBN:9 7 8 - 0 - 4 4 3 - 3 3 7 4 2 - 0
- eBook ISBN:9 7 8 - 0 - 4 4 3 - 3 3 7 4 3 - 7
Fundamentals of the Hybrid Metal Extrusion and Bonding Process details this novel solid-state welding method (HYB) that utilizes continuous rotary extrusion as a technique to ena… Read more
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Fundamentals of the Hybrid Metal Extrusion and Bonding Process details this novel solid-state welding method (HYB) that utilizes continuous rotary extrusion as a technique to enable metallurgical bonding between different metals and alloys by aluminum filler metal additions. Due to its versatility and flexibility the process can be applied to solid-state plate surfacing and additive manufacturing, each of which is also outlined in the book. The book starts with an overview of the current challenges involved with welding aluminum alloys, including those associated with conventional fusion welding and friction stir welding of age-hardening Al-Mg-Si alloys. Readers will gain insight into how the properties achieved depend on both the chemical composition and the applied thermomechanical processing and heat treatment schedules. Simple analytical models are presented for rapid assessment of the response of the alloys to welding, and sections on diffusion and intermetallic compound formation during multimaterial joining and modeling and simulation of the thermal, microstructural, and strength evolution fields during welding are also discussed. From there, the book then introduces the HYB method and how it can help overcome those commonly-encountered welding challenges. Following chapters outline the design of the extruder tool, explain how to tailor the process, how to select the tool material and coating, and how to design the cooling, wire feeding, and control systems. The book concludes with a chapter providing guidance on optimization and upscaling, demonstrating the competitive advantages HYB has over conventional welding methods such as gas metal arc welding, laser beam welding, and friction stir welding.
- Step-by-step guide to this novel solid-state welding method that utilizes continuous rotary extrusion as a technique to enable metallurgical bonding between different metals and alloys by aluminum filler metal additions
- Outlines recent advances in solid-state welding and additive manufacturing involving the use of aluminum filler metal additions
- Discusses metallic bonding in aluminum welds, common fatigue properties, modeling for rapid assessment of alloys to welding, simulations of the thermal, microstructural, and strength evolution fields during welding, and more
Researchers, advanced students, and professionals in additive manufacturing, metal manufacturing, welding, and materials science
1. Metallurgical Challenges in Welding Aluminum Alloys and the Necessity for New Innovative Process Development
2. The HYB PinPoint Extruder and its Applications
3. Fundamentals of the HYB process
4. The essential details of the HYB PinPoint extruder design
5. Interchangeable extruder heads and optimised welding conditions for different joint configurations and materials combinations
6. Selection of tool steel and heat treatment procedures
7. Effect of different tool steel surface coatings on the HYB filler wire feeding
8. How to design the cooling system for the HYB PinPoint extruder
9. How to design the HYB wire feeding system
10. How to design the HYB process control system
11. Principle guidelines for optimisation and upscaling of the HYB process
2. The HYB PinPoint Extruder and its Applications
3. Fundamentals of the HYB process
4. The essential details of the HYB PinPoint extruder design
5. Interchangeable extruder heads and optimised welding conditions for different joint configurations and materials combinations
6. Selection of tool steel and heat treatment procedures
7. Effect of different tool steel surface coatings on the HYB filler wire feeding
8. How to design the cooling system for the HYB PinPoint extruder
9. How to design the HYB wire feeding system
10. How to design the HYB process control system
11. Principle guidelines for optimisation and upscaling of the HYB process
- Edition: 1
- Published: March 1, 2026
- Language: English
ØG
Øystein Grong
Øystein Grong (born in 1956) received his PhD degree from the Norwegian University of Science and Technology (NTNU) in 1983. He has worked as a conscripted Researcher at the Norwegian Defence Research Establishment, Kjeller, Norway and as a Visiting Research Professor at Colorado School of Mines, Golden, Colorado and National Institute of Standards and Technology, Boulder, Colorado (USA). He was appointed Professor of Metallurgy at the Norwegian University of Science and Technology in 1987 by the King of Norway and the Prime Minister. Professor Grong has a broad interest and research experience in materials in general and microstructural modelling in particular. The emphasis is on industrial manufacturing methods such as welding, brazing, casting, extrusion and heat treatment. A significant part of this work is related to research-based innovation and new process and product developments. During his time at NTNU Professor Grong has educated 74 MSc and 26 PhD students and written 303 publications, including 110 major scientific papers in referred international journals. He is also the author of the well reputed international textbook Metallurgical Modelling of Welding, which formerly was ranked among the top ten books (best sellers) 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 full-time involved in the development of the Hybrid Metal Extrusion & Bonding (HYB) process together with industry partners and colleagues at the Department of Mechanical and
Industrial Engineering, NTNU.
Affiliations and expertise
Department of Mechanical and Industrial Engineering, NTNU, Norway