Joining of EN AW 6060 Pipes by Plastic Forming

The article deals with an innovative, but not widely used type of joining of aluminum pipes through experiments. The joints are formed by plastic forming. The process is carried out in one step using the principle of pipe expansion, in order to bring the mating surfaces of the two pipes into a suitable position for the subsequent joining, which is created by means of plastic instability and simultaneous pressure flanging. Experimental tests were carried out with the tools designed to create most suitable joints. The length of the plastically formed pipe sections involved in the joint, the angle of the sharpened pipe ends, and the thickness of the formed joints were analyzed. One of the main goals of this study is to determine the proper joining parameters, such as tool distance or edge tapering for further investigations. As per the test results, it can be stated that the technology is suitable for joining aluminum tubes in a cost-effective way, and based on the promising strength results, further investigations will be conducted.