Mechanical properties and joining mechanisms of Al-Fe magnetic pulse welding by spot form for automotive application

Yao, Yuanheng; Jing, Lijun; Wang, Shaoluo; Li, Guangyao; Cui, Junjia; Tang, Xiao‐Han; Jiang, Hao

doi:10.1016/j.jmapro.2022.02.017

Cited by 27 publications

(7 citation statements)

References 26 publications

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“…MPW has been effectively utilised on several combinations of metals [7,8]. Numerous investigations have been conducted on the phenomena occurring at the interface and the mechanisms of bonding in magnetic pulse welding.…”

Section: Introductionmentioning

confidence: 99%

Study on interfacial morphologies of AA1060 and SS321 magnetic pulse welded joints

Su,

Wang,

et al. 2024

Mater. Res. Express

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In this study, the application of magnetic pulse welding was employed for the production of tubular joints using 1060 aluminium and 321 stainless steel. Two crucial process parameters, the charging voltage, and the gap between the outer and inner tubes, were subjected to mechanical property tests and morphology analysis. The joints that exhibited favourable mechanical properties were obtained with a gap size of 1.25mm and a charging voltage exceeding 3.5 kV. The presence of intermetallic compounds at the joint interface indicates the occurrence of fusion in the transition zone. The quantity of molten metal increased with an increase in the charging voltage. The aluminium content in the intermetallic compounds within the transition zone decreased as one moved from the 1060 aluminium side towards the 321 stainless steel side. The gap distance plays an important role in determining the efficiency of energy transformation at the joint interface during magnetic pulse welding (MPW). A smaller gap distance resulted in a substantial amount of energy being transformed into plastic deformation in the transition zone. Conversely, a greater gap distance led to a significant amount of energy from the electrical charging voltage being converted into thermal energy. The MPW joint consisted of bonding, mechanical interlock, and non-bonding regions. The mechanical properties of the joint were influenced by the composition of the intermetallic compound. Taking into account the impact of morphologies and elastic modulus of the transition zone, an increase in the melting of stainless steel during the welding process was found to be advantageous for the MPW of 1060 aluminium to 321 stainless steel.

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Section: Introductionmentioning

confidence: 99%

Study on interfacial morphologies of AA1060 and SS321 magnetic pulse welded joints

Su,

Wang,

et al. 2024

Mater. Res. Express

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“…Magnetic pulse welding (MPW) is a joining process commonly known for welding dissimilar metals at the solid state. This technique is phenomenologically similar to explosive welding (EXW), but it is an eco-friendly process thanks to the use of an electromagnetic impulse as a driving force [1][2][3]. This welding process completes less than 100 us with a high-speed collision which forms the interface material at a very high-strain rate of 10 6 -10 7 s −1 [4][5][6].…”

Section: Introductionmentioning

confidence: 99%

Determining the weldability window based on the interface morphologies formed during high-speed collision in magnetic pulse welding

Raoelison

Sapanathan

et al. 2023

Science and Technology of Welding and Joining

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This paper aims to determine the weldability window in magnetic pulse welding, via computational and experimental analysis of the Al/Cu interface material response during the high-speed collision. The results reveal that the interface morphologies (straight, various type waves, vortices, cavities) arise from the differences in thermal and kinematic instabilities in between the aluminium side and copper side. The analysis of the percentage of straight and wavy morphologies based on the impact velocity versus impact angle allows to predict the weldability window which is potentially 'L' shaped with a convex shape tendency. Therefore, the proposed Eulerian model is robust enough to accurately predict the interface morphologies, and be used as tool to non-destructively depict the weldability window for an impact welding.

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“…[4]. Al-Fe alloy is mainly used for metal welding, which has the advantages of lightweight structure and good overall performance and has a wide range of prospects for application in the aerospace, nuclear energy, automotive, and electrical and electronic industries [5].…”

Section: Introductionmentioning

confidence: 99%

Estimation of Activity and Molar Excess Gibbs Energy of Binary Liquid Alloys Al-Cu, Al-Ni, and Al-Fe from the Partial Radial Distribution Function Simulated by Ab Initio Molecular Dynamics

Lu,

Chen,

Zhang

et al. 2023

Metals

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To accurately and conveniently obtain the thermodynamic data of binary liquid alloys, a new method is proposed in this study. It combines ab initio molecular dynamics (AIMD) simulation with a thermodynamic model to estimate the activity and molar excess Gibbs energy of binary liquid alloys. Additionally, two methods of grouping the partial radial distribution function (PRDF) of 5000 steps obtained by simulation are proposed for the first time. The PRDF of Al50Cu50, Al50Ni50, and Al50Fe50 is obtained by AIMD simulation. These PRDF are combined with four thermodynamic models to estimate the activity and molar excess Gibbs energy. Furthermore, the estimation results of the four models are compared with those of the Miedema model. The results show that when the first peak of the PRDF is obtained by the symmetric method, the average relative deviation (ARD) of the activity and molar excess Gibbs energy of the four models are, respectively: 28% and 32% for Molecular Interaction Volume Model (MIVM); 162% and 38% for Regular Solution Model (RSM); 508% and 65% for Wilson model; 562% and 67% for Non-Random Two-Liquid (NRTL). When the first peak of PRDF is obtained by non-symmetric method, the average ARD of the activity and molar excess Gibbs energy of the four models are, respectively: 64% and 20% for MIVM; 115% and 26% for RSM; 661% and 70% for Wilson; 727% and 72% for NRTL. In addition, the average ARD of the activity and molar excess Gibbs energy of the Miedema model are 113% and 33%. These data indicate that the estimation performance of the MIVM model is superior to the other four models, and the symmetric method performs better than the non-symmetric method. The grouping treatment of PRDF data effectively improves estimation performance.

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Mechanical properties and joining mechanisms of Al-Fe magnetic pulse welding by spot form for automotive application

Cited by 27 publications

References 26 publications

Study on interfacial morphologies of AA1060 and SS321 magnetic pulse welded joints

Study on interfacial morphologies of AA1060 and SS321 magnetic pulse welded joints

Determining the weldability window based on the interface morphologies formed during high-speed collision in magnetic pulse welding

Estimation of Activity and Molar Excess Gibbs Energy of Binary Liquid Alloys Al-Cu, Al-Ni, and Al-Fe from the Partial Radial Distribution Function Simulated by Ab Initio Molecular Dynamics

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