Experiment and Numerical Analysis of Deformation and Collision Behavior during Al/Cu Magnetic Pulse Welding

To investigate high-speed deformation and collision behavior during Al/Cu magnetic pulse welding, experiment and numerical analysis were performed. An Al plate and a Cu plate were used for a flyer plate and a parent plate, respectively. Charging energy stored in a capacitor and a gap between the plates were changed in the range from 1.0 kJ to 6.0 kJ and from 1.0 mm to 2.5 mm, respectively. The charging energy from 4.0 kJ to 6.0 kJ were available to weld them with the gap from 1.5 mm to 2.5 mm. In contrast, when the charging energy of 3.0 kJ was used, the welding was achieved at the gap in 2.0 mm and 2.5 mm. Numerical analysis of deformation behavior revealed that the Al flyer plate deforms like a cantilever beam. The initial collision velocity increased with increasing the charging energy and the gap of plates. Whereas, the initial collision angle increased with only increasing the gap of plates and it did not depend on the charging energy. As the collision progressed, the collision velocity decreased and the collision angle increased.