Foil acuator welding device design, prototype manufacturing and applications

Vaporizing foil actuator welding is a manufacturing method that has come to the forefront for small-scale applications and overcomes the limitations of traditional welding methods. In particular, it provides seamless joining of different metals and allows a superior production in this respect. In this thesis study, a prototype was designed and manufactured for evaporated foil actuator welding, which is one of the solid state welding methods and developed as a new explosion welding method in the world, and experimental studies were carried out. Such innovative manufacturing methods play an important role in industrial applications and different metal joining needs. Our study is important in terms of contributing to manufacturing technologies research and the development of this new technology. In the manufactured prototype, the electrical energy stored through direct current (DC) capacitors was directed to the joining area, the actuator foil was evaporated and the welding process was carried out for the materials stacked on the foil. SEM analysis results on welded samples were evaluated and interpreted. In addition, risk analysis was performed and interpreted to determine safe working steps for vaporizing foil actuator welding, a new technique.