An A1050 aluminum sheet was collided against a steel mold with a small V-shaped through-thickness groove by using magnetic pulse forming (MPF) at various charging energy conditions. Deformation behavior of the sheet was also reproduced by using a series of numerical analyses. The groove was filled at high charging energy condition. Almost no change in grain morphology was observed at the mid-thickness area of the sheet, but extremely large intensive deformation occurred at the metal surface region along the slope of the mold. Deformation of the MPFed Al sheet was numerically analyzed by using ANSYS Emag-Mechanical. Electromagnetic force and deformation of the sheet was reproduced, and the impact velocity of the sheet to the mold was obtained. Deformation behavior of Al under various impact velocity conditions was analyzed by using Smoothed Particle Hydrodynamics (SPH) method of ANSYS AUTODYN. The groove was completely filled with Al at the high impact velocity condition, and an extremely large plastic strain and strain rate were observed only at the sheet surface. These simulation results corresponded very well to the final shape and the local microstructure change observed in the MPFed Al sheet.
Magnetic pulse welding (MPW) which is one of the impact welding methods is suitable for a wide variety of combinations of similar and dissimilar metals. The flyer plate is accelerated by electromagnetic force and collided to the parent plate. A characteristic wavy interface is formed. The impact velocity and impact angle of the flyer plate during impact are important parameters which affect the interface morphology. In the case of dissimilar metals (e.g. Al/Cu, Al/Fe), the intermediate layer (such as intermetallic compound (IMC)) is formed by wavy interface formation and local temperature increase. The intermediate layer often decreases the bonding strength. Wavy interface formation mechanism and temperature increase at the joint interface should be investigated in order to obtain the dissimilar metal joint with high bonding strength. In this study, the impact velocity and impact angle of the flyer plate were obtained by using ANSYS Emag-Mechanical. Based on the obtained impact velocity and impact angle of the flyer plate in the MPW, the wavy interface formation and temperature change were reproduced by using ANSYS Autodyn for solving non-liner dynamics problems. Al sheets and Cu sheets were joined by the MPW. The joint interface was observed by OM and SEM and compared to the simulation result.
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