Experimental Study and Numerical Simulation of Interfacial Morphology by Electromagnetic Pulse Welding with Aluminum to Steel

Electromagnetic pulse welding is a new promising method for solid-state joining of dissimilar materials. However, little understanding the dynamic phenomena that leads interface morphology and intermetallic compounds to change. Initially, using Ansys Maxwell proved eddy current heat had softening effect on aluminum alloy, could press into stainless steel in semi-melted state. IMCs layer transferred from unwelded zone (FeAl) flat welded (Fe2Al5+FeAl2+FeAl) wave (α-Al+FeAl3), state jet determined performance. Then, these insights were verified by SPH simulation, dispersed made soft alloy produce interface, beam particles wrapped produced interface. Combination shear tests, with high strength was characterized large waveform, molten metal small amount particles, formed Al-rich FeAl3. The seam low shown brittle fracture characteristic spherical iron-rich FeAl retention jets. Therefore, dominant mechanism formation compression impact accompanied alloy.