Joining Dissimilar Materials by Magnetic Pulse Spot Welding

Paper #:
  • 2017-01-0474

Published:
  • 2017-03-28
Abstract:
The use of dissimilar materials in the aim of reducing vehicles weight is increasing in the automotive industry and therefore joining between different types of materials became a priority especially between aluminum and steel as well as between metals and fiber-reinforced composites. The presented work will discuss a solution developed by Ecole Centrale de Nantes in collaboration with FAURECIA Group for welding aluminum to steel (and galvanized steel) using the magnetic pulse spot welding (MPSW) as well as a new patented process for hybrid joining of metals to fiber-reinforced composites based on the MPSW. In both cases, the explanation of the principle will be found first to go after that through the experimental applications achieved to study the process feasibility where the strength of the joining in both cases was tested and presented good results. Furthermore, the microstructure of the joint interface using SEM analysis was verified and in the case of metal to composites joining, the effects on the composite microstructure (i.e. cracks and fibers state) were also checked using X-Ray microtomography. Finally, analytical calculations and fully-coupled (electromagnetic-thermal-mechanical) numerical simulations (using LS-Dyna) predicting the most important parameters of the process are presented.
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