Numerical Simulation Study on Magnetic Pulse Welding for Tube-Mandrel Hybrid Structure Made by Aluminum Alloy/steel

The magnetic pulse welding of hybrid structure consisting of a 3003 aluminum alloy outer tube and Q235 steel mandrel was simulated numerically by LS-DYNA®. The formation process of the joint, the influence of process parameters on collision velocity and collision angle were observed and analyzed. The findings indicated that the deformation of the outer tube was uniform in radial section, while the collision angles generated in the axial section. The increase of discharge energy increased the velocity and acceleration of the outer tube, but had little effect on the collision angle. Additionally, a longer collision distance resulted in the greater collision velocity and collision angle. The results could provide guidance for the practical application of magnetic pulse welding of tube-mandrel hybrid structure.