Investigation and Improvement of dissimilar Aluminum-Copper Joining using Magnetic Pulse Welding combined with local Inert Gas Application
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Date
2025-08-26
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Abstract
Well-performing electrical conductors and contacting processes are crucial for a variety
of industries and applications, including flat conductors such as busbars. The challenge is
to manufacture relevant systems with excellent properties in a cost-efficient and ecological
way. From a materials science perspective, one approach could be the utilization of
aluminum in electrical systems. This is because aluminum is a better conductor than
copper with regard to its weight. However, the exclusive use of aluminum is limited by the
constraints of electrical systems that require the partial use of copper. This can be due to
space limitations or connections to the power electronics, which are predominantly copper
components. Hybrid systems consisting of aluminum, copper and dissimilar joints between
both materials have been identified as a viable solution. However, the fabrication of these
joints is challenging for conventional fusion welding processes due to chemical and
thermophysical incompatibilities. Magnetic Pulse Welding (MPW) is a solid-state welding
process which, due to its characteristic low energy input, allows a resource efficient
fabrication of dissimilar joints. However, the limitations of MPW and their expandability,
its potential for future applications, and the interactions of the process parameters with
observed joint properties have not been sufficiently researched. Consequently, this study
addresses MPW in the field of joining flat conductors by investigating the correlations
between process parameters and mechanical, microstructural, and electrical joint
properties. Furthermore, an inert gas supply during joining is investigated in order to
determine the potential for improvement of the weldability and the resulting joint
properties.
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Keywords
Magnetic Pulse Welding, Electrical Joint Characterization, local Inert Gas Application, Dissimilar Materials
Subjects based on RSWK
Elektromagnetisches Pulsschweißen, Werkstoff, Inertgas, Aluminium, Kupfer, Verbindungstechnik