The Suppression of Intermediate Layer in Al-Cu Electromagnetic Pulse Welding with Double Coils Structure
Li Chengxiang1, Wang Xianmin1,2, Zhou Yan1, Weng Shiyu1, Shu Yihang1
1. State Key Laboratory of Power Transmission Equipment Technology Chongqing University Chongqing 400044 China; 2. Electric Power Planning and Construction Research Center of Yunnan Electric Power Grid Co. Ltd Kunming 650011 China
Abstract：Electromagnetic pulse welding (EMPW), an advanced solid-phase welding technology for dissimilar metals, has garnered extensive applications across domains such as electric power transmission, automotive manufacturing, and refrigeration equipment due to its distinctive advantages. However, the Al-Cu joints welded by this technique encounter challenges regarding forming an intermediate layer comprising intermetallic compounds and cracks at the weld seam, which reduces the weld's mechanical performance. Based on the formation mechanism of the interface morphology and the necessary conditions for electromagnetic pulse welding, a method to regulate the electromagnetic pulse welding interface using a dual-coil structure was proposed. This method aimed to suppress the generation of the intermetallic compound intermediate layer in the weld seam by diminishing the horizontal component of the movement velocity at the welding interface, thereby reducing the shear effect at the interface. To validate the efficacy of this approach, an electromechanical coupled finite element simulation model was utilized to compare the electromagnetic parameter distribution characteristics during the EMPW process based on single and dual-coil structures. The experimental results from the high-speed camera verified the simulation of the plate movement process and results revealed that the horizontal component of interface velocity decreased by using the dual-coil structure. A scanning electron microscope was employed to analyze the micro-morphology of the welding interface. The results showed that the welding interface based on a dual-coil structure mainly included the wave and straight types, while the interface via single-coil included the vortex type. The findings indicated that joints welded using a single-coil structure EMPW method exhibited a pronounced intermediate layer at the interface. In contrast, those welded using the double-coils structure EMPW method failed to show the formation of an intermediate layer at the interface, exhibiting a reduced shear effect on the interface morphology and superior mechanical properties. Besides, the line scanning results of the welding interface based on a dual-coil structure reflect a monotonic change in elements, while the welding interface of a single-coil structure exhibits regional oscillations in elements. Overall, the effectiveness of this method in suppressing the formation of intermetallic compounds was validated at the interface. Utilization of a dual-coil structure can reduce the shear effect at the interface by controlling the horizontal component of the plastic flow, thereby suppressing the formation of intermetallic compounds and enhancing the tensile performance of the welded joints. This study contributes to understanding the physical mechanisms of the electromagnetic pulse welding process, which is of great significance for the research and development of high-performance, lightweight heterogeneous metal composite materials and the advancement of lightweight manufacturing.
李成祥, 王现民, 周言, 翁诗雨, 舒一航. 基于双线圈结构的铝-铜电磁脉冲板件焊接中间层抑制方法[J]. 电工技术学报, 2025, 40(13): 4112-4124.
Li Chengxiang, Wang Xianmin, Zhou Yan, Weng Shiyu, Shu Yihang. The Suppression of Intermediate Layer in Al-Cu Electromagnetic Pulse Welding with Double Coils Structure. Transactions of China Electrotechnical Society, 2025, 40(13): 4112-4124.
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2025, Vol. 40 
