Effects of surface coatings on the joint formation during magnetic pulse welding in tube-to-cylinder configuration

Magnetic Pulse Welding (MPW) is a joining technique favorable for the generation of strong atomic bonded areas between different metals, e.g. aluminum and steel. Brittle intermetallic phases can be avoided due to the high-speed collision and the absence of external heat. The demand for the use of this technique in industries like automotive and plant engineering rises. However, workpieces used in these fields are often coated, e.g. in order to improve the corrosion resistance. Since the weld quality depends on the material's behavior at the collision zone, surface layers in that region have to be taken into account as well. This work investigates the influences of different coating types. Aluminum to steel welding is used as an example system. On the inner steel part (C45) coatings like zinc, nickel and chrome are applied, while the aluminum flyer tubes (EN AW-6060) are anodized, chromated and passivated. Welding tests are performed using two different welding systems with varying discharging frequencies and four geometrical part setups. For all combinations, the flyer velocity during the process is measured by Photon Doppler Velocimetry (PDV). By using the uncoated material combination as a reference, the removal of surface layers due to jetting is analyzed. Finally, the weld quality is characterized in peel tests, shear-push tests and by the help of metallographic analysis. It is found that certain coatings improve the joint formation, while others are obstructive for the performance of MPW. Some coatings have no influence on the joining process at all.