Formation mechanism of waveform interface in Mg/Al electromagnetic pulse welding

L Zhang and YL Hu and XM Duan and X Li and LM Yin and YH Chen and J Xie, MATERIALS TODAY COMMUNICATIONS, 45, 112401 (2025).

DOI: 10.1016/j.mtcomm.2025.112401

The wavy interface, a characteristic feature of electromagnetic pulse welding (EMPW), remains a subject of ongoing debate regarding its formation mechanisms. Through molecular dynamics (MD) simulations of the EMPW process, this study reveals that the periodic interfacial undulations originate from the reciprocating erosion dynamics between the metal jet expelled from the flying plate and the substrate surface, ultimately generating alternating crest-trough morphology. Systematic parametric analysis demonstrates that interfacial morphology undergoes phase transitions governed by impact velocity. furthermore, an optimal impact angle of approximately 20 degrees facilitates the formation of the wavy interface. Microstructural characterization confirms significant grain refinement at the collision interface, with the joint strength exhibiting positive correlation to discharge energy. Notably, at 35 kJ discharge energy, the joint strength reaches 35.1 MPa, approximating the base aluminum material's strength (38 MPa). This strength equivalence induces fracture location transition from the welded interface to the aluminum substrate.

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