Role of collision angle during dissimilar Al/Cu magnetic pulse welding

Pourabbas, Mehdi; Abdollah-zadeh, A.; Sarvari, Morteza; Movassagh-Alanagh, Farid; Pouranvari, M.

doi:10.1080/13621718.2020.1768351

Cited by 13 publications

(5 citation statements)

References 27 publications

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“…However, even in the cross-section in Figure 5b, no continuous melted layer of these thicknesses was visible. These findings are in good agreement with the literature [11][12][13][14][15][16]33]. Li et al described the formation of intermediate zones, especially waves and vortices, by local melting due to local plastic deformation causing high shear instabilities and an adjacent inter-diffusion layer of 70 nm thickness, formed below the melting point of aluminum combined with ultrahigh heating and cooling rates of about 10 13 K s −1 [14,15].…”

supporting

confidence: 90%

“…Therefore, several studies have been conducted on this topic in recent years. It was focused on how different process parameters influence the formation of the weld interface with interdiffusion layers, intermetallic layers and resulting defects [11][12][13][14][15] and how these parameters can be optimized to obtain highquality welds in terms of mechanical and electrical properties [16][17][18][19].…”

Section: Introductionmentioning

confidence: 99%

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The Energy Balance in Aluminum–Copper High-Speed Collision Welding

Groche

Niessen

2021

JMMP

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Collision welding is a joining technology that is based on the high-speed collision and the resulting plastic deformation of at least one joining partner. The ability to form a high-strength substance-to-substance bond between joining partners of dissimilar metals allows us to design a new generation of joints. However, the occurrence of process-specific phenomena during the high-speed collision, such as a so-called jet or wave formation in the interface, complicates the prediction of bond formation and the resulting bond properties. In this paper, the collision welding of aluminum and copper was investigated at the lower limits of the process. The experiments were performed on a model test rig and observed by high-speed imaging to determine the welding window, which was compared to the ones of similar material parings from former investigation. This allowed to deepen the understanding of the decisive mechanisms at the welding window boundaries. Furthermore, an optical and a scanning electron microscope with energy dispersive X-ray analysis were used to analyze the weld interface. The results showed the important and to date neglected role of the jet and/or the cloud of particles to extract energy from the collision zone, allowing bond formation without melting and intermetallic phases.

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supporting

confidence: 90%

Section: Introductionmentioning

confidence: 99%

The Energy Balance in Aluminum–Copper High-Speed Collision Welding

Groche

Niessen

2021

JMMP

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“…The dissimilar metallurgical joining of Al and Cu can be achieved via the formation of three types of interfaces, including solid/solid interface (e.g. diffusion bonding [5], magnetic pulse welding [6], ultrasonic welding [7], friction stir welding [1, 4, 8]) where welding peak temperature is below the melting temperature of Al, solid/liquid interface (e.g. laser brazing [9], resistance spot welding (RSW) [10, 11], diffusion brazing [12]) where Al alloy or interlayer experiences melting and wets the solid Cu and liquid/liquid interface (where the heat input is so high enabling melting of both Al and Cu side).…”

Section: Introductionmentioning

confidence: 99%

Metallurgical joining of aluminium and copper using resistance spot welding: microstructure and mechanical properties

Zare

Pouranvari²

2021

Science and Technology of Welding and Joining

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This paper investigates the melting phenomena, joining mechanism, microstructure evolution, and mechanical properties of the Al/Cu dissimilar joints made using resistance spot welding. A metallurgical bonding between Al and Cu is achieved via the reaction-diffusion between liquid Al and solid Cu (i.e. brazing mechanism). The reaction layer was featured by the in-situ formation of an ultra-thin Cu-rich Al-Cu intermetallic compound at the joint interface, on-cooling formation of coarse and thick θ-Al 2 Cu as the primary phase for hyper-eutectic solidification and formation of ultrafine lamellar α-Al/θ -Al 2 Cu eutectic structure. It is shown that the peak load and energy absorption of the Al/Cu joints are controlled by the effective length of the solid/liquid reaction zone and the thickness of the θ -Al 2 Cu primary solidification phase.

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“…2020, 4, x FOR PEER REVIEW 2 of 19 [2,3]. The consolidation between the two parts occurs without any bulk melting [4], although local melting at scattered locations along the joint interface is reported for MPW of AA6060 flyer tubes and copper target rods [5], AA1050 flyer and target sheets [6] and AA6060 flyer tubes and AlSi10Mg target rods [7]. For the overlapping assembly, the outer part is referred to as the flyer and the inner part is referred to as the target.…”

Section: Introductionmentioning

confidence: 99%

Probing Magnetic Pulse Welding of Thin-Walled Tubes

Faes

Shotri

2020

JMMP

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Magnetic pulse welding is a solid-state joining technology, based on the use of electromagnetic forces to deform and to weld workpieces. Since no external heat sources are used during the magnetic pulse welding process, it offers important advantages for the joining of dissimilar material combinations. Although magnetic pulse welding has emerged as a novel technique to join metallic tubes, the dimensional consistency of the joint assembly due to the strong impact of the flyer tube onto the target tube and the resulting plastic deformation is a major concern. Often, an internal support inside the target tube is considered as a solution to improve the stiffness of the joint assembly. A detailed investigation of magnetic pulse welding of Cu-DHP flyer tubes and 11SMnPb30 steel target tubes is performed, with and without an internal support inside the target tubes, and using a range of experimental conditions. The influence of the key process conditions on the evolution of the joint between the tubes with progress in time has been determined using experimental investigations and numerical modelling. As the process is extremely fast, real-time monitoring of the process conditions and evolution of important responses such as impact velocity and angle, and collision velocity, which determine the formation of a metallic bond, is impossible. Therefore, an integrated approach using a computational model using a finite-element method is developed to predict the progress of the impact of the flyer onto the target, the resulting flyer impact velocity and angle, the collision velocity between the flyer and the target, and the evolution of the welded joint, which are usually impossible to measure using experimental observations.

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Role of collision angle during dissimilar Al/Cu magnetic pulse welding

Cited by 13 publications

References 27 publications

The Energy Balance in Aluminum–Copper High-Speed Collision Welding

The Energy Balance in Aluminum–Copper High-Speed Collision Welding

Metallurgical joining of aluminium and copper using resistance spot welding: microstructure and mechanical properties

Probing Magnetic Pulse Welding of Thin-Walled Tubes

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