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<p>The aim of this study is to investigate micro welding processes of different metal pairs using vaporized foil actuator welding (VFAW): Cu (0.1&#xa0;mm)–Cu (0.1&#xa0;mm), Cu (0.5&#xa0;mm)–Cu (0.5&#xa0;mm), 1090 Al-1090 Al, and Cu-1090 Al. The input charging energies of the capacitor bank for the welding processes were 1.0&#xa0;kJ for Cu (0.1&#xa0;mm)–Cu (0.1&#xa0;mm), 2.0 and 1.8&#xa0;kJ for Cu (0.5&#xa0;mm)–Cu (0.5&#xa0;mm), 1.5&#xa0;kJ for 1090 Al-1090 Al, and 2.3&#xa0;kJ for Cu-1090 Al. Welding of plates and wires was also conducted for the NiTi (wire)–Cu. The input energy was 1.6&#xa0;kJ. All the investigated metal pairs were welded with each other. A smooth particle hydrodynamics (SPH) model was developed to investigate the mechanism of tail vortex formation by analyzing the particle velocities at the post-collision side interface. When the collision velocity and collision angle increase, the wavelength and amplitude of the interfacial wave generated at the welding interface due to the impact continue to increase. The rotation angle of particles at the tail vortex gradually becomes higher, leading to a more pronounced phenomenon of the tail vortex. When the collision velocity ranges from 700 to 900&#xa0;m/s and the collision angle varies between 8° and 20°, the vortex phenomenon gradually becomes more pronounced, ultimately resulting in the formation of a complete circle. Dissimilar impact welding of NiTi (wire)–Cu provides stronger joining and more design flexibility, compared to mechanical joining, positioning the technology to be a solution to producing high-strength actuators and sensors.</p>

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Micro-welding process of dissimilar metals using metal foil vaporization

  • 期刊论文

  • 发表日期：

    2025年9月23日

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  • Sheng Cai,
  • Shifa Zhang,
  • Wang Liu,
  • Yuhang Sun,
  • Cong Yu,
  • Yiqi Wang

摘要

The aim of this study is to investigate micro welding processes of different metal pairs using vaporized foil actuator welding (VFAW): Cu (0.1 mm)–Cu (0.1 mm), Cu (0.5 mm)–Cu (0.5 mm), 1090 Al-1090 Al, and Cu-1090 Al. The input charging energies of the capacitor bank for the welding processes were 1.0 kJ for Cu (0.1 mm)–Cu (0.1 mm), 2.0 and 1.8 kJ for Cu (0.5 mm)–Cu (0.5 mm), 1.5 kJ for 1090 Al-1090 Al, and 2.3 kJ for Cu-1090 Al. Welding of plates and wires was also conducted for the NiTi (wire)–Cu. The input energy was 1.6 kJ. All the investigated metal pairs were welded with each other. A smooth particle hydrodynamics (SPH) model was developed to investigate the mechanism of tail vortex formation by analyzing the particle velocities at the post-collision side interface. When the collision velocity and collision angle increase, the wavelength and amplitude of the interfacial wave generated at the welding interface due to the impact continue to increase. The rotation angle of particles at the tail vortex gradually becomes higher, leading to a more pronounced phenomenon of the tail vortex. When the collision velocity ranges from 700 to 900 m/s and the collision angle varies between 8° and 20°, the vortex phenomenon gradually becomes more pronounced, ultimately resulting in the formation of a complete circle. Dissimilar impact welding of NiTi (wire)–Cu provides stronger joining and more design flexibility, compared to mechanical joining, positioning the technology to be a solution to producing high-strength actuators and sensors.