Feasibility Study on Joining Aluminum Tube with Alumina Ceramic Rod Using Magnetic Pulse Crimping Process
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Date
2025-08-26
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Abstract
Ceramic-metal joints play a vital role in structural applications, offering benefits such as
strength, lightweight, high strength-to-weight ratio, corrosion resistance, and high temperature
performance. These joints are widely used in fields ranging from electronics
and biomedical devices to aerospace and automotive industries. However, joining ceramics
and metals is challenging due to differences in atomic bonding and thermal expansion
properties. Traditional methods, such as brazing, friction welding, and fusion welding, often
induce thermal stresses and residual strain, leading to defects like cracks and intermetallic
formation at the joint interface. Magnetic Pulse Crimping (MPC) is an environmentally
friendly, quick, and cold solid-state material joining process that does not create heat affected
zones and mitigates these issues. This study uses the MPC process to investigate the
feasibility of joining an AA 1050 aluminum alloy tube with an alumina ceramic rod. The
experiments were performed at various discharge energies using an Archimedean spiral coil
and a step taper field shaper to evaluate the joint's strength and metal-ceramic interface
behavior. Non-sinusoidal waviness patterns have been observed at the metal-ceramic joint
interface. The numerical analysis used the LS DYNA EM module to measure the current
density, magnetic field, Von Mises stresses, and impact velocity on the flyer tube. The
manuscript contributes to the understanding of ceramic-metal joining under
electromagnetic forming conditions.
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Keywords
Magnetic Pulse Crimping, Ceramic-metal joints, Alumina, AA 1050, Archimedean spiral coil
Subjects based on RSWK
Crimpen, Aluminiumrohr, Keramik-Metall-Verbund, Machbarkeit, Aluminiumoxide, Aluminiumlegierung