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In this work, the vaporizing foil actuator welding (VFAW) has been used for impact welding of aluminum AA1060 to copper T2 sheets. The microstructural feature, mechanical properties, and electrical conductivity of Al-Cu welded joints were investigated. The VFAW process was simulated by LS-DYNA to analyze the effect of impact velocity and angle. The evolution of the microstructure of the welding interface was revealed by smoothed particle hydrodynamics numerical simulation. The qualities of Al-Cu joints were evaluated by microstructure observations, lap shear tensile testing and resistance measurements. The results show that the Al-Cu joints have a flat welding interface at the discharge voltage of 8 kV, but the joints failed at the interface due to the residual Al2O3. Owing to the change in interfacial effective plastic strain and impact pressure, increasing the discharge voltage resulted in the transition of the interface waveform from flat to wavy, and the site of tensile failure changed from the welding interface to the Al base metal. The results of element analysis showed that there was a transition zone consisting of Al-Cu intermetallic compounds at the interface. This transition zone would change from intermittent to continuous and become thicker after increasing the discharge voltage. Variations in discharge voltage can change the resistivity, thickness, and area of the welding region, which in turn affects the joint resistance.
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JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
ISSN: 1059-9495
Year: 2024
2 . 2 0 0
JCR@2023
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ESI Highly Cited Papers on the List: 0 Unfold All
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