Finite element analysis of multi-physics coupling for electromagnetic welding of aluminum/steel dissimilar metals

Wang Yan; Xiong Zhilin; Ning Zhaoyang; Chen Jinlan

doi:10.7513/j.issn.1004-7638.2024.03.026

Volume 45 Issue 3

Jul. 2024

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Wang Yan, Xiong Zhilin, Ning Zhaoyang, Chen Jinlan. Finite element analysis of multi-physics coupling for electromagnetic welding of aluminum/steel dissimilar metals[J]. IRON STEEL VANADIUM TITANIUM, 2024, 45(3): 188-194. doi: 10.7513/j.issn.1004-7638.2024.03.026

Citation:

Wang Yan, Xiong Zhilin, Ning Zhaoyang, Chen Jinlan. Finite element analysis of multi-physics coupling for electromagnetic welding of aluminum/steel dissimilar metals[J]. IRON STEEL VANADIUM TITANIUM, 2024, 45(3): 188-194. doi: 10.7513/j.issn.1004-7638.2024.03.026

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Finite element analysis of multi-physics coupling for electromagnetic welding of aluminum/steel dissimilar metals

doi: 10.7513/j.issn.1004-7638.2024.03.026

1.
School of Mechanical Engineering, Hunan Industry Polytechnic, Changsha 410208, Hunan, China
2.
Hunan Engineering Research Center of Intelligent Flexible Machining Technology for Complex Thin-walled Precision Parts, Changsha 410208, Hunan, China

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Received Date: 2023-02-15
Publish Date: 2024-07-02

Abstract

Abstract

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 (d_s) and driving plate thickness (t_d). 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 microstructure under the optimal process parameters was analyzed. The analysis of variance shows that the maximum impact velocity for high-quality welding can be obtained under V =15 kV, d_s =1.5 mm and t_d =1 mm.
- aluminum/steel dissimilar metal,
- electromagnetic welding (EMW),
- finite element,
- electromagnetic-thermal-structure coupling,
- response surface method

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References(16)

References

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