Finite element analysis of multi-physics coupling for electromagnetic welding of aluminum/steel dissimilar metals
The reaction of aluminum/steel dissimilar metals welded joints to form Fe-Al intermetallic compounds deteriorates joint performance and makes welding forming difficult.In this paper,ABAQUS finite element software was used to simulate the electromagnetic-thermal-structure coupling process of dissimilar metal electromagnetic welding(EMW)to achieve high-quality aluminum/stainless steel welding with minimal energy.The experiment was designed based on the Box-Behnken response surface method,and important parameters were extracted from the process parameters such as voltage(V),separation distance(ds)and driving plate thickness(td).By drawing the Al/stainless steel welding process window,the possibility of weld formation was studied,and the validity of the EMW simulation results was verified by experiments.In order to evaluate the joint forming quality,the joint microstruc-ture under the optimal process parameters was analyzed.The analysis of variance shows that the max-imum impact velocity for high-quality welding can be obtained under V=15 kV,ds=1.5 mm andtd=1 mm.
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