Evaluating the Electromagnetic Welding Parameters for Improving the Mechanical Properties of Al–Cu Joint

The aim of this study is to simultaneously improve ultimate tensile strength, elongation, weld length and hardness of Al–Cu welded sheets by optimizing the electromagnetic welding parameters such as voltage, standoff distance and distance between spacers. Finite element analysis was conducted for the electromagnetic welding of Al–Cu sheets, and the results were used to predict the formation of weld. The experimental tests were then executed by response surface methodology in order to extract the regression models for predicting the optimal values of the parameters. The assessment of the weld quality was performed by observation of the microstructure of weld interface using the optical and scanning electron microscopes. The mechanical properties of Al–Cu weld were improved simultaneously using the desirable values of parameters as validated by confirmation experiments. It was also observed from the weld microstructure that the most important potential sources for reducing the weld length and weld strength are the high thickness intermetallic layers with micro-cracks and the entrapped oxides in the weld interface.