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This paper aims to determine the weldability window in magnetic pulse welding, via computational and experimental analysis of the Al/Cu interface material response during the high-speed collision. The results reveal that the interface morphologies (straight, various type waves, vortices, cavities) arise from the differences in thermal and kinematic instabilities in between the aluminium side and copper side. The analysis of the percentage of straight and wavy morphologies based on the impact velocity versus impact angle allows to predict the weldability window which is potentially ‘L’ shaped with a convex shape tendency. Therefore, the proposed Eulerian model is robust enough to accurately predict the interface morphologies, and be used as tool to non-destructively depict the weldability window for an impact welding.

Determining the weldability window based on the interface morphologies formed during high-speed collision in magnetic pulse welding