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<p>This study develops a coupled finite element method-smoothed particle hydrodynamics (FEM-SPH) model to elucidate interfacial evolution mechanisms during magnetic pulse-assisted semi-solid brazing (MPASSB) of copper-aluminum tubular joints. Through an integrated numerical-experimental approach, we systematically examined the interdependent effects of impact parameters (velocity <i>v</i>, angle <i>θ</i>) and filler metal characteristics (apparent viscosity <i>μ</i>, spatial distribution) on interfacial morphology development. Key findings reveal that impact parameters (<i>v</i>, <i>θ</i>) predominantly govern interfacial waveform attributes: both wavelength and amplitude exhibit positive correlations with increasing impact velocity and angle. Reduced filler metal viscosity (<i>μ</i> &lt; 41.7&#xa0;Pa·s) promotes interfacial wave formation and vortex generation, while increased filler-copper spacing enhances copper-side waveform definition. Experimental validation through parametric brazing trials confirmed the synergistic effects of <i>v</i> and <i>μ</i> on interfacial wave dimensions. Microstructural analysis demonstrates aluminum-side porosity originates from particle entrapment in semi-solid filler metal, where enhanced fluidity facilitates pore migration. Conversely, copper-side porosity arises from oxide residue accumulation, mitigated through viscosity optimization. High-strain-rate collision dynamics generate sequential jetting phenomena: primary jets induce interfacial mixing while re-entrant jets establish periodic waveform patterns through cyclic material interaction.</p>

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Magnetic pulse-assisted semi-solid brazing of copper-aluminum tubes: solid-liquid interface and defect formation

  • 期刊论文

  • 发表日期：

    2026年3月7日

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  • Jiawang Zhang,
  • Shangyu Huang,
  • Zhenghua Meng,
  • Jianhua Hu,
  • Zhenglei Rui

摘要

This study develops a coupled finite element method-smoothed particle hydrodynamics (FEM-SPH) model to elucidate interfacial evolution mechanisms during magnetic pulse-assisted semi-solid brazing (MPASSB) of copper-aluminum tubular joints. Through an integrated numerical-experimental approach, we systematically examined the interdependent effects of impact parameters (velocity v, angle θ) and filler metal characteristics (apparent viscosity μ, spatial distribution) on interfacial morphology development. Key findings reveal that impact parameters (v, θ) predominantly govern interfacial waveform attributes: both wavelength and amplitude exhibit positive correlations with increasing impact velocity and angle. Reduced filler metal viscosity (μ < 41.7 Pa·s) promotes interfacial wave formation and vortex generation, while increased filler-copper spacing enhances copper-side waveform definition. Experimental validation through parametric brazing trials confirmed the synergistic effects of v and μ on interfacial wave dimensions. Microstructural analysis demonstrates aluminum-side porosity originates from particle entrapment in semi-solid filler metal, where enhanced fluidity facilitates pore migration. Conversely, copper-side porosity arises from oxide residue accumulation, mitigated through viscosity optimization. High-strain-rate collision dynamics generate sequential jetting phenomena: primary jets induce interfacial mixing while re-entrant jets establish periodic waveform patterns through cyclic material interaction.