Forming Process, Morphology and Properties of AA1060/DP690T Magnetic Pulse Welded Joints

YU Peng; ZHANG Timing; CHEN Yuhua; YE Zhikang; XIE Jilin; WANG Shanlin; ZHANG Shiyi

doi:10.3969/j.issn.1674-6457.2026.02.012

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (2) : 123-133. DOI: 10.3969/j.issn.1674-6457.2026.02.012

Advanced Joining Technology

Forming Process, Morphology and Properties of AA1060/DP690T Magnetic Pulse Welded Joints

YU Peng, ZHANG Timing^*, CHEN Yuhua, YE Zhikang, XIE Jilin, WANG Shanlin, ZHANG Shiyi

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Abstract

The work aims to investigate the influence of process parameters on the microstructure and mechanical properties of the interface of AA1060/DP690T dissimilar metal magnetic pulse welded joints and the effect of nickel plating of the substrate on the joint properties. Welded joints were prepared by magnetic pulse welding equipment, and the effects of process parameters on the microstructure and mechanical properties of the joints were systematically investigated through microstructure observation, energy spectrum analysis, electron backscattering technique and shear strength test. In addition to this, the effect of nickel plating on the performance of the joints was investigated. The highest shear strength of the joints was obtained at a discharge energy of 30 kJ and an initial gap of 1.5 mm, reaching 82.5% of the strength of the aluminum parent material AA1060. The average grain size of the interfacial intermetallic compound (IMC) (0.8 µm) was significantly smaller than that of AA1060 (15 µm) and AA1060 (5 µm), and the indentation depth of the aluminum base material (1 000 nm)<depth of the IMC layer (570 nm)<depth of the steel base material (420 nm), the interface showed the typical hardness transition characteristics. As the discharge energy increased, the interface IMC thickness increased from 3 µm to 20 µm, and the interface failure mode changed from ductile fracture to brittle fracture. At a discharge energy of 30 kJ and an initial gap of 1.5 mm, the maximum shear load of AA1060/nickel-plated DP690T decreased by 22.7% from 4.65 kN to 3.59 kN, and the elongation length increased from 3.02 mm to 4.78 mm, which was a 57.9% increase in elongation length, as compared with that of the joints with AA1060/ DP690T. The intermediate hardness property of the IMC layer (between the two parent materials) realizes the gradient transition of mechanical properties, thus relieving the residual stress caused by the difference in the coefficients of thermal expansion of aluminum/steel, and enhancing the joint performance; the nickel-plated layer makes the joints change from strength-dominated to toughness-dominated, which is more suitable for impact-resistant engineering applications.

Key words

magnetic pulse welding / AA1060/DP690T dissimilar materials / discharge energy / initial gap / morphology / mechanical properties

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YU Peng, ZHANG Timing, CHEN Yuhua, YE Zhikang, XIE Jilin, WANG Shanlin, ZHANG Shiyi. Forming Process, Morphology and Properties of AA1060/DP690T Magnetic Pulse Welded Joints[J]. Journal of Netshape Forming Engineering. 2026, 18(2): 123-133 https://doi.org/10.3969/j.issn.1674-6457.2026.02.012

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