Construction of physical welding windows for magnetic pulse welding of 5754 aluminum with DC04 steel

Magnetic pulse welding (MPW) has potential applications where fusion welding is problematic, such as in dissimilar joints or where the very part integrity, as in electronic components, is likely to be impaired by hot environments. Mostly suited in lap configuration, its successful implementation hinges on multiple process parameters such as standoff distance between two parts, the discharge energy and the shape of inductor amongst others. From fundamental point, the impact angle and velocity are governing factors and remain difficult to apprehend via experimental approach. Numerical simulation is a viable tool to apprehend the effect of process parameters on impact angle and velocity and subsequently outline a physical weldability zone. On the contrary, the process weldability zone is experimentally determined for dissimilar joints made from A5754 on to DC 04 steel by varying the discharge energy and standoff distance using a straight I shape conductor. The shear strength of the joints is used as a marker to define the process weldability zone. Results suggest that weldability is reduced by increasing the discharge energy and standoff distance and a combination of two is required to optimize the outcome. The paper proposes to discuss process and physical weldability zones determined through numerical simulation and experimental tests.