Effects of Standoff Distance on Magnetic Pulse Welded Joints Between Aluminum and Steel Elements in Automobile Body
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Effects of Standoff Distance on Magnetic Pulse Welded Joints Between Aluminum and Steel Elements in Automobile Body Junjia Cui1 · Shaoluo Wang1 · Wei Yuan1 · Guangyao Li1 Received: 29 March 2020 / Accepted: 19 June 2020 © China Society of Automotive Engineers (China SAE) 2020
Abstract In industrial production, the standoff distance of magnetic pulse welding (MPW) is a critical parameter as it directly affects welding quality. However, the effects of standoff distance on the physical properties of MPW joints have not been investigated. Therefore, in this study, aluminum alloy (AA5182) sheets and high-strength low-alloy steel (HC340LA) sheets were welded through MPW at a discharge energy of 20 kJ, under various standoff distances. Thereafter, mechanical tests were performed on the MPW joints, and the results indicate that there is a significant change in the shear strength of the AA5182/ HC340LA-welded joints with respect to the standoff distance. When the standoff distance ranges from 0.8 to 1.4 mm, the strength of the joint is higher than that of the base AA5182 sheet. Microscopic observations were conducted to analyze the interfacial morphology, element diffusion behavior, and microdefects on the welding interface of the AA5182/HC340LA joints. The AA5182/HC340LA joint with a standoff distance of 1.4 mm possesses the longest welded region and the largest interfacial wave. This interfacial wave pattern is suitable for achieving MPW joints with high shear strengths. Keywords Magnetic pulse welding · Aluminum/steel joints · Standoff distance · Mechanical properties · Microstructures
1 Introduction The application of lightweight and high-performance multimaterial structures in automobile bodies is an effective approach to realizing light vehicles [1–4]. For instance, a composite structure with a reasonable combination of aluminum and steel offers advantages of both materials and achieves an optimal comprehensive performance, with a significant reduction in the weight of the vehicle body [5–7]. However, the thermal and physical parameters of aluminum alloys and steels differ considerably; moreover, the solubility of Fe in Al is significantly small. Furthermore, achieving high-quality joints through conventional fusion welding is relatively difficult [8, 9]. Magnetic pulse welding (MPW) is a high-speed solid-state welding technology, whereby welding is performed at room temperature without any heat affected zones; therefore, the above-mentioned aluminum
* Guangyao Li [email protected] 1
State Key Laboratory of Advanced Design and Manufacturing for Vehicle Body, Hunan University, Changsha 410082, China
and steel welding problems can be effectively avoided using this technology [10–12]. In recent years, several studies have focused on the MPW of dissimilar materials. In particular, in Refs. [13–16], the authors systematically analyzed and applied the MPW technology on dissimilar materials. Cui et al. [13] studied the effect of the surface treatment of AA5182 on the strength of AA5182/HC340LA joints. Their result
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