Abstract
Electromagnetic Pulse Welding (MPW) is a solid state bonding process which makes use of a high velocity impact, driven by the dynamics of an electromagnetic-mechanical phenomena, to produce a bond. The impact of a very fast moving plate onto the base metal causes localized plastic deformation, solid state bonding and the formation of ripples in the interface, whose formation mechanism has no consensus in the literature. Since there is no heat or melting involved, dissimilar metals, with different metallurgical and thermal properties can be welded by this technique. Tubes and sheets, with several combinations of dissimilar materials, have already been welded by MPW. Aluminum-copper (Al/Cu) joints are in demand for electronics, electric power transfer, heat exchangers, etc., however, bonding using techniques based in melting are very difficult due to their physical properties mismatch. The present research work aims to use MPW as an alternative process to weld Al to Cu, as well as to better understand the relationship between the different process parameters, such as flyer thickness/geometry, impact angle, energy and impact velocity on the morphology, strength and microscopic properties of the bond zone. The results of this work give valuable insights regarding the welding mechanism and the weldability window for Al/Cu combinations.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Bhattacharya, T.K., Das, H., Jana, S.S., Pal, T.K.: Numerical and experimental investigation of thermal history, material flow and mechanical properties of friction stir welded aluminum alloy to dhp copper dissimilar joint. Int. J. Adv. Manuf. Technol., 1–15 (2016)
Kush, P.M., Vishvesh, J.B.: A review on dissimilar friction stir welding of copper to aluminum: Process, properties, and variants. Mater. Manuf. Process. 31(3), 233–254 (2016)
Lee, W., Bang, K., Jung, S.: Effects of intermetallic compound on the electrical and mechanical properties of friction welded cu/al bimetallic joints during annealing. J. Alloy. Compd. 390(12), 212–219 (2005)
Chuang, T.H., Tsao, L.C., Tsai, T.C., Yeh, M.S., Wu, C.S.: Development of a low-melting-point filler metal for brazing aluminum alloys. Metallurg. Mater. Trans. A 31(9), 2239–2245 (2000)
Lee, S.J., Nakamura, H., Kawahito, Y., Katayama, S.: Effect of welding speed on microstructural and mechanical properties of laser lap weld joints in dissimilar Al and Cu sheets. Sci. Technol. Weld. Join. 19(2), 111–118 (2014)
Ouyang, J., Yarrapareddy, E., Kovacevic, R.: Microstructural evolution in the friction stir welded 6061 aluminum alloy (t6-temper condition) to copper. J. Mater. Process. Technol. 172(1), 110–122 (2006)
Yilbas, B.S., Sahina, A.Z., Kahramanb, N., Al-Garnia, A.Z.: Friction welding of st-al and al-cu materials. J. Mater. Process. Technol. 49(3), 431–443 (1995)
Stern, A., Shribman, V., Ben-Artzy, A., Aizenshtein, M.: Interface phenomena and bonding mechanism in magnetic pulse welding. J. Mater. Eng. Perform. 23(10), 3449–3458 (2014)
Ben-Artzy, A., Stern, A., Frage, N., Shribman, V., Sadot, O.: Wave formation mechanism in magnetic pulse welding. Int. J. Impact Eng. 37(4), 397–404 (2010)
Ben-Artzy, A., Stern, A., Frage, N., Shribman, V.: Interface phenomena in aluminum: magnesium magnetic pulse welding. Sci. Technol. Weld. Join. 13(4), 402–408 (2008)
Beyer, E., Brenner, B., Gobel, G., Herrmannsdrfer, T., Kaspar, J.: Insights into intermetallic phases on pulse welded dissimilar metal joints. In: 4th International Conference on High Speed Forming-2010
Hoseini, A., Behzad, T.: Weldability window and the effect of interface morphology on the properties of al/cu/al laminated composites fabricated by explosive welding. Mater. Des. 86, 516–525 (2015)
Cowan, G.R., Bergmann, O.R., Holtzman, A.H.: Mechanism of bond zone wave formation in explosion-clad metals. Metallurg. Mater. Trans. B 2(11), 3145–3155 (1971)
Hunt, J.N.: Wave formation in explosive welding. Philos. Mag. 17(148), 669–680 (1968)
Robinson, J.L.: The mechanics of wave formation in impact welding. Philos. Mag. 31(3), 587–597 (1975)
Gobel, G., Kaspar, J., Herrmannsdorfer, T., Brenner, B., Beyer, E.: Insights into intermetallic phases on pulse welded dissimilar metal joints. In: 4th International Conference on High Speed Forming-2010
Raoelison, R., Sapanathan, T., Buiron, N., Rachik, M.: Magnetic pulse welding of al/al and al/cu metal pairs: Consequences of the dissimilar combination on the interfacial behavior during the welding process. J. Manuf. Process. 20, 112–127 (2015)
Wu, X., Shang, J.: An investigation of magnetic pulse welding of al/cu and interface characterization. J. Manuf. Sci. Eng. 136(5), 051002 (2014)
Yu, H., Xu, Z., Fan, Z., Zhao, Z., Li, C.: Mechanical property and microstructure of aluminum alloy-steel tubes joint by magnetic pulse welding. Mater. Sci. Eng. A 561, 259–265 (2013)
Tan, C.W., Jiang, Z.G., Li, L.Q., Chen, Y.B., Chen, X.Y.: Microstructural evolution and mechanical properties of dissimilar Al–Cu joints produced by friction stir welding. Mater. Des. 51, 466–473 (2013)
Zhang, Y.: Investigation of magnetic pulse welding on lap joint of similar and dissimilar materials. PhD thesis, The Ohio State University, 2010
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2017 Springer International Publishing AG
About this chapter
Cite this chapter
Oliveira, I.V., Cavaleiro, A.J., Taber, G.A., Reis, A. (2017). Magnetic Pulse Welding of Dissimilar Materials: Aluminum-Copper. In: Silva, L. (eds) Materials Design and Applications. Advanced Structured Materials, vol 65. Springer, Cham. https://doi.org/10.1007/978-3-319-50784-2_31
Download citation
DOI: https://doi.org/10.1007/978-3-319-50784-2_31
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-50783-5
Online ISBN: 978-3-319-50784-2
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)