Experimental and Numerical Analyses of Wavy Interface Formation and Local Melting Phenomena at the Magnetic Pulse Welded Al/Fe Joint Interface

Abstract

A 1050-O aluminum plate and a low carbon steel (SPCC) plate were seam welded by magnetic pulse welding (MPW). Experimental and numerical analysis methods were combined to investigate the wavy interface formation and local melting phenomena at the Al/Fe joint interface. The metallographic observation results showed that Al/Fe joint interface presents a trigger-like wave shape with two types of intermediate layers intermittently formed at the interface. Collision angle between two plates and impact velocity of Al sheet driven by electromagnetic force was numerically solved by coupled mechanical and electromagnetic fields analysis. The metal jet emission behavior, wavy interface formation process and the temperature change during MPW collision process was analyzed by SPH method. The numerical results showed that the temperature near the interface exceeds the melting point of both Al and Fe at extremely high pressure, which leads to the formation of a local melting zone (LMZ) where Al and Fe were mixed in melted state. The numerically reproduced wavy interface morphology showed a good consistency with the experimentally observed results.

Interfacial Microstructure and Strength of Magnetic Pulse Welded A5052 Aluminum Alloy/SPCC Steel Lap Joint

“…investigated the magnetic pulse welded Al/steel interface using both experimental and numerical analyses and reported the temperature change at the welding interface. 24,25) These reports showed that at the welding interface, the temperature rises above the melting point of base metal and then cools rapidly. In addition, the dendritic structure at welding interface was reported in the joints formed by using explosive welding which is a kind of the impact welding method, and it is concluded that the formation of the dendritic structure resulted from local melting and successive solidification.…”