Investigation of coil deformation and metallurgical variations at the interface of dissimilar Aluminum-Copper Joints in magnetic pulse welding using Single-Sided and double-sided coil

Sarvari, Morteza

doi:10.24200/nst.2025.1791.2102

Investigation of coil deformation and metallurgical variations at the interface of dissimilar Aluminum-Copper Joints in magnetic pulse welding using Single-Sided and double-sided coil

Articles in Press

Document Type : Research Paper

Author

Morteza Sarvari

assistant professor of NSTRI

https://doi.org/10.24200/nst.2025.1791.2102

Abstract

In this study, magnetic pulse welding (MPW) is proposed as a solid-state welding solution for the metallurgical joining of dissimilar aluminum-copper metals. The coil type used in MPW is a critical factor influencing joint quality, depending on its geometry and electromagnetic performance. Two types of flat coil, a double-sided H-shaped coil and a single-sided E-shaped coil, were used for welding dissimilar aluminum-copper metals. Welding was performed at a discharge voltage of 16 kV, a capacitor bank of 120 μF, and an air gap of 0.7 mm. After 10 welding repetitions, the coils’ morphology was evaluated. The joint interface was analyzed using field emission scanning electron microscopy (FE-SEM). Examination of the coils showed that the double-sided inductor underwent plastic deformation after 10 welds due to magnetic field interference. This deformation increased the coil-workpiece gap, reducing process repeatability.The results of the electron microscope examination of the joint interface showed the formation of a transition zone, a wavy morphology, waves, and separated copper pieces at the joint interface. The formation of the transition zone occurred only in welding with a double-sided coil, which indicates a much higher impact intensity in the type of coil compared to the single-sided coil. Also, the width of the joint interface in welding using a single-sided coil has decreased from 3.5 μm to 0.6 μm compared to the double-sided coil.

Keywords

Magnetic pulse welding

double-sided coil

single-sided coil

Aluminum

Copper

transition zone

Main Subjects