Joining of Al-Alloy Tubes by Carbon Steel Tubes using MPW Technique

• Published in: Indian journal of science and technology 2024-06, Vol.17 (24), p.2538-2546
• Main Authors: Gnanamurugan, K, Varahamoorthi, R, Sundarraj, C
• Format: Article
• Language: English
• ISSN: 0974-6846; 0974-5645
• DOI: 10.17485/IJST/v17i24.177

Background/ Objectives: Joining aluminum alloys with low carbon steel (DC01) through fusion welding is a challenging task due to the occurrence of solidification defects like porosity, alloy segregation, and hot cracking. However, these issues can be addressed by employing solid-state welding techniques like explosive welding and MPW (magnetic pulse welding). MPW is a cost-effective and high-speed solid state welding method that involves creating joints in an overlap configuration. Methods: The MPW technique was employed to join dissimilar aluminum alloy AL 7075T6 hollow tube and DC01 steel rod in this study. A central composite design model was created to analyze the relationship between key MPW process parameters, including stand-off distance (SoD), overlap length, and discharge energy, and the bonding strength of the joints. Experimental setups were established and correlate with tensile-shear fracture load and interface hardness of the joints with the MPW process parameters. Findings: It is understood that the maximum TSFL of 2.404 kN was obtained under the welding condition of 23kJ discharge energy, 2.25 mm Stand-off distance, 8.5 mm overlap length, which is the optimum MP welding state for AA 7075 T6 with DC01 and confirmed by RSM. In addition, the cultivated connection can be aptly leveraged to anticipate the TSFL of MPW joints with a 95% confidence level. Novelty: The parametric mathematic samples were developed for forecasting TSFL of joints. The MPW parameters were optimized to enhance TSFL of joints. Aluminium alloys with low carbon steel joints were developed using MPW for cars and ships applications without fusion welding defects. Keywords: Magnetic Pulse Welding, Dissimilar Joint, (RSM) Response Surface Methodology, Tensile Shear-Fracture Load