Aluminum mixed metal welding applications joint by magnetic pulse welding, MPW

In this paper the mechanical performance under crash and fatigue loading situations of welded dissimilar metals using the magnetic pulse technology is discussed. Aluminum and mixed aluminum-steel joints were prepared using magnetic pulse welding (MPW). Investigations on coupon samples were performed under oscillating and monotone (crash) loadings until failure. Durability analysis of the joint specimens was performed combined with FEM analysis, applying the notch stress concept. The endurable notch stresses were compared to reference S-N curves derived for conventional welded samples. The results for the MPW joints fit well in the scatter band of the conventional laser-welded joints. This is the verification that the notch stress concept can be successfully applied also for MPW joints. The crash performance of the MPW joint was first investigated in lap-shear and peel tests at different strain rates. Based on these results a T-joint component was designed and manufactured. The derived FE-modelling concept for crash behavior was validated by comparison of component tests and simulation. Finally an outlook is given for local micro testing of the weld strength.