Experimental and Numerical Investigations into Magnetic Pulse Welding of Aluminum Alloy 6016 to Hardened Steel 22MnB5

By means of magnetic pulse welding (MPW), high-quality joints can be produced without some the disadvantages conventional welding, such as thermal softening, distortion, and other undesired temperature-induced effects. However, range materials that have successfully been joined by MPW is mainly limited to comparatively soft copper or aluminum. This paper presents an extensive experimental study leading a process window for successful aluminum alloy 6016 (AA6016) hardened 22MnB5 steel sheets. defined impact velocity angle AA6016 flyer. These parameters, which are significantly dependent on initial gap between flyer target, charging energy power generator, lateral position in relation inductor, were determined macroscopic coupled multiphysics simulation LS-DYNA. The welded samples mechanically characterized lap shear tests. Furthermore, bonding zone was analyzed optical scanning electron microscopy including energy-dispersive X-ray spectroscopy well nanoindentation. It found exhibited wavy interface transition consisting Al-rich intermetallic phases. Samples with thin therefore crack-free zones showed 45% higher tensile strength resulting failure base material.