Investigation on Interface Analysis and Process Simulation of Electromagnetic Pulse Welding for Automotive Copper Terminal/Aluminum Conductor Joints

To suppress the formation of brittle intermetallic compounds typically generated during conventional joining of Cu/Al dissimilar materials in the automotive lightweighting sector, this study examines the interface properties and process simulation of electromagnetic pulse welding technology for connecting copper terminals to aluminum conductors. High-quality welds exhibit a wavy interface composed of interpenetrating metallic phases, according to microstructural research. To represent workpiece dynamics, magnetic field distribution, and impact behavior under discharge voltages ranging from 4 to 5.5 kV, a linked electromagnetic-structural finite element model was developed. According to simulation data, increasing the discharge voltage significantly enhances impact pressure, strain rate, and magnetic flux density, all of which support strong contact bonding. The study offers a reference for the lightweight production of automobile electrical connectors by demonstrating the impact of process factors on weld quality.