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<p>In this paper, the magnetic pulse-assisted semi-solid brazing (MPASSB) technology is innovatively applied to realize the connection of Cu/Al tubes. Through finite element simulation, an in-depth analysis of the clamping and brazing forming processes within the MPASSB method is conducted. Concurrently, by examining the microstructure of the joint, the study explores the mechanism of filler metal shear rheology in the formation of joint defects, oxide removal, and metallurgical bonding. The findings demonstrate that continuous shear rheological behavior of the filler metal during the brazing forming process critically facilitates oxide layer removal while enabling elemental diffusion across the joint interface. Notably, no brittle Cu/Al intermetallic compounds (IMCs) were detected. Instead, Al<sub>4.2</sub>Cu<sub>3.2</sub>Zn<sub>0.7</sub> phase was identified at the copper-side (Cu-side) interface. Mechanical performance testing reveals that the extent of oxide removal at the interface is a decisive factor affecting the joint’s mechanical properties. The maximum shear strength of the joint is 78.8&#xa0;MPa; however, when an oxide layer is present at the interface, the shear strength drops to 53.3&#xa0;MPa, with fracture occurring at the oxide layer. Therefore, although the forming time of the MPASSB method is extremely short, it can achieve interfacial metallurgical bonding and obtain high-quality brazed joints, which provide a new approach for the efficient connection of Cu/Al tubes.</p>

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Magnetic pulse-assisted semi-solid brazing of Cu/Al tubes: finite element simulation and experimental analysis

  • 期刊论文

  • 发表日期：

    2025年8月12日

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  • Zhenglei Rui,
  • Shangyu Huang,
  • Huajun Wang

摘要

In this paper, the magnetic pulse-assisted semi-solid brazing (MPASSB) technology is innovatively applied to realize the connection of Cu/Al tubes. Through finite element simulation, an in-depth analysis of the clamping and brazing forming processes within the MPASSB method is conducted. Concurrently, by examining the microstructure of the joint, the study explores the mechanism of filler metal shear rheology in the formation of joint defects, oxide removal, and metallurgical bonding. The findings demonstrate that continuous shear rheological behavior of the filler metal during the brazing forming process critically facilitates oxide layer removal while enabling elemental diffusion across the joint interface. Notably, no brittle Cu/Al intermetallic compounds (IMCs) were detected. Instead, Al4.2Cu3.2Zn0.7 phase was identified at the copper-side (Cu-side) interface. Mechanical performance testing reveals that the extent of oxide removal at the interface is a decisive factor affecting the joint’s mechanical properties. The maximum shear strength of the joint is 78.8 MPa; however, when an oxide layer is present at the interface, the shear strength drops to 53.3 MPa, with fracture occurring at the oxide layer. Therefore, although the forming time of the MPASSB method is extremely short, it can achieve interfacial metallurgical bonding and obtain high-quality brazed joints, which provide a new approach for the efficient connection of Cu/Al tubes.