Magnetic pulse welding of multi-material connections

Copper alloys possess high electrical and thermal conductivity as well as excellent chemical stability. Due to the fast-occurring developments in the electronics sector, the copper demand has been increasing over the last years and the copper price has been rising accordingly. Another disadvantage to its use, is the high density of this material, which leads to a high component weight and contradicts current trends of lightweight design.
Hence, for economic and ecological reasons, in some sectors - as e.g. the automotive industry – and due to legal requirements related to reduction of emissions, it is desirable to substitute copper by an alternative material as much as possible. Especially in this case, aluminium is a good candidate, because its electrical and thermal conductivity is about 60% of that of copper, while costs per weight unit are only about 40% and density is even only about 30% of the according values of copper.
Against this background, the H2020 JOIN’EM project, funded by the EC has been put in motion. In JOIN’EM, 14 partners from the industry and scientific institutes coming from Germany, Austria, France, Belgium, Italy, and Spain are researching together under the coordination of the Fraunhofer Institute of Machine Tools and Forming Technology – IWU to replace parts which are currently made from copper, by hybrid aluminium copper parts. These will consist mainly of aluminium, while copper is maintained only in regions where it is indispensable, e.g. as a thin layer. Thus, significant cost and weight savings are possible.
The Fraunhofer IWU presented a paper on the above topic that you can find here:
Magnetimpulsschweißen erleichtert die Herstellung von Mischverbindungen (Original, German version)
Feel free to download it, and contact us for any questions you might have!