Effect of welding gap on electromagnetic pulse welding of a copper-aluminum alloy joint

Electromagnetic pulse welding (EMPW) is commonly used for welding copper and aluminum alloy. The welding gap is important in the EMPW process. The research focused on the effect of welding gap on the welding process and the mechanical property of joints. During the EMPW experiments, the deformation, collision, and metal jet were recorded with a high-speed camera. The joint mechanical property was tested. SEM and EDS were employed to examine the bonding interface. Results indicated that the welding gap length did not significantly influence the aluminum alloy plate motion behavior when it was long enough. With the welding gap width increasing, the collision velocity initially increased and subsequently decreased, and the angle between the two plates when they first collided increased continuously. The intensity and duration of the metal jet and the joint mechanical properties also increased first and then decreased. The welding marks widened first and then narrowed.