Magnetic pulse welding of dissimilar aluminum- copper joints: Impact of downscaling on weldability
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Date
2025-08-26
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Abstract
Due to the higher specific electrical conductivity (conductivity/weight) of aluminum
compared to copper and the associated lightweight potential, the electrical industry is
moving towards current-conducting components made of aluminum. However, the use of
aluminum is associated with a necessity for hybrid aluminum-copper joints, due to space
limitations as well as purchased components are often made of copper. Furthermore, it can
be observed that numerous flat conductors, such as those used in DC and asynchronous
motors, are only a few millimeters wide. Due to the rapidly growing market for electric
vehicles, an increasing demand for aluminum-copper dissimilar joints with small
dimensions is consequently to be expected.
In contrast to conventional fusion welding processes, magnetic pulse welding (MPW) is
suitable for joining aluminum-copper dissimilar joints, due to the minimization of brittle
intermetallic phases. This is attributed to the low energy input, which is applied as the
movement of mass to fabricate a material continuous joint.
It is known that MPW reaches its process limits when the dimensions of the joining partners
decreases due to the minimization of effective eddy currents. However, these limits are still
insufficiently researched. Consequently, this investigation is intended to reveal the process
limitations of MPW with regard to the joining partner dimensions. For this purpose, various
geometries are evaluated with regard to their weldability and the resulting microstructural,
mechanical and electrical properties.
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Keywords
magnetic pulse welding, joining partner dimension, aluminum-copper dissimilar joints
Subjects based on RSWK
Elektromagnetisches Pulsschweißen, Aluminium, Kupfer, Schweißnaht