The necessity of the multi-layered aluminium (Al) tabs to copper (Cu) busbars for electric vehicle (EV) batteries is increasing. Electromagnetic pulse welding (EMPW) applicable conductive dissimilar/similar materials. In this work, three Al sheets and a single Cu sheet are joined by EMPW technology. layer-wise tensile lap shear properties Al–Cu joint evaluated. interfacial microstructures parallel perpendicular direction studied scanning electron microscopy (SEM) transmission (TEM)...

Electromagnetic pulse welding (EMPW) is an environmentally friendly and advanced manufacturing technology. Researches find the macro-morphology of EMPW joint sheets presents a multilayer ellipse. The experiments Al-Cu Al-Mg were carried out, both micro-morphology showed there collision zone, bonding zone affecting in joint, presenting elliptical morphology, which was independent material. welded seam zone. 3D multiphysics simulation results also that distribution plastic deformation Al...

Prognostic and health management (PHM), which could provide the ability of fault detection (FD), isolation (FI) estimation remaining useful life (RUL), has been applied to detect diagnose device faults assess its status, with aiming enhance reliability, safety, reduce maintenance costs. In this paper, taking an aircraft fuel system as example, virtual instrument technology computer simulation technology, integrated approach signal processing method model-based is introduced build software...

In the dissimilar metal welding field, electromagnetic pulse (EMPW) is a kind of potential technology. To further reveal bonding mechanism EMPW, this work carried out Cu–Al sheet EMPW experiment with discharge voltage 15 kV and gap 1.5 mm. It analyzed microstructure formation joint interface transition layer in detail by SEM, EDS, TEM, FIB. The was found at vortex zone, there an isolated long strip Cu particle separated from main body sheet. tested results showed that contained Al-rich...

As a non-heat input solid-state joining technology, electromagnetic pulse welding (EMPW) has many advantages in the connection of dissimilar metals. Finite element (FE) methods are often used to design EMPW equipment, explore parameters and analyze transient process. However, it is difficult reflect effect directly. This work proposed evaluation model based on window theory Vc-β trajectory curve obtained FE simulation. A coupling circuit-magnetic-structure field was established COMSOL...

Electric vehicle is one of the important development directions automotive industry, with a broad prospect. The high-voltage wire harness plays key role in power system for electric vehicle. Aluminum was proposed to be crimped copper terminal instead harness, which can decrease weight and cost. This work proposes an electromagnetic pulse crimping technology connect aluminum A 28 kJ established reliable joints were obtained tested. microstructure analysis results show that connection...

Electromagnetic pulse crimping (EMPC) technology is expected to be applied the connection of high-voltage (HV) wiring harnesses and terminals for electric vehicle (EV). As an important part EMPC system, assembly field shaper coil can directly affect effect EMPC. An system was established in this work, including control part, energy storage capacitor bank, discharge switch, coil, shaper. The relationship between structure parameters analyzed through experiment Al tubes. results showed that...

The subject of Structural Health Monitoring (SHM) is emerging as an area interest for aerospace, mechanical and automotive industry. It defined a system with the ability to continuously automatically monitor physical states structure outer environment by means embedded or attached sensors. Then, SHM can interpret adverse changes caused damage intention improving structure's reliability reducing maintenance cost. Therefore, key implementation that knows what in look how identify them....

Electromagnetic pulse spot welding technology (EPSW) has great application prospects in the field of electric vehicles due to realization without gasket. The EPSW Cu/Al alloy this article is carried out two steps. first step uses electromagnetic force pre-process aluminum plate punch a hump through forming (EMPF). second realize between and copper plate. This studied effects stamping with discharge voltage 10 kV 15 compared coils different widths. results show: gasket was realized; higher...

Electromagnetic pulse welding (EMPW) is commonly used for copper and aluminum alloy. The gap important in the EMPW process. research focused on effect of process mechanical property joints. During experiments, deformation, collision, metal jet were recorded with a high-speed camera. joint was tested. SEM EDS employed to examine bonding interface. Results indicated that length did not significantly influence alloy plate motion behavior when it long enough. With width increasing, collision...

Abstract This paper presents a set of numerical simulations on the effect rotation thermal convection in shallow model Czochralski configuration with heated crucible bottom. Results show that when bottom is by low heat flux, temperature fluctuation can be significantly weakened and melt kept from solidifying. Once flux exceeds threshold value, thermocapillary will transit to Benard–Marangoni convection. The amplified increasing crystal rate or flux. restrain azimuthal traveling waves....

A series of three-dimensional numerical simulations were performed to understand the thermal-solutal capillary-buoyancy flow Ge1-xSix melts during Czochralski crystal growth with a rotating or crucible. The and crucible rotation Reynolds numbers in this work are 0∼3.5 × 103 (0∼4.4 rpm) 0∼−2.4 (0∼−1.5 rpm), respectively. Simulation results show that if thermal capillary number is relatively low, will be steady axisymmetric, even though rotates at constant rate. critical for initiation...

In this work, we developed a snake algorithm to approach for the detection of edge microcirculation blood vessel images from microscope. The process are image sequences obtained microscope-television system. difficulty is bad quality. was based on dual active contour model overcome some problems conventional snakes. Two contours extended initial used as inner and outer contour. We then apply dynamic programming search minimization within domain. results show that method can detect object in...

The morphologies of the interfaces in electromagnetic pulse welding joints have a significant impact on their bonding strength and therefore garnered attention from researchers. In this study, hydrodynamic model was developed to systematically analyze effects horizontal vertical components velocity interface morphology evolution during welding. An experimental platform with capacity 28 kJ/20 kV constructed utilized perform unidirectional bidirectional collision Al-Cu Al-Al joints. simulation...

A pulsed magnetic field forces metals to collide violently and form metallurgical bonding in electromagnetic pulse welding (EMPW). Because of its advantages fast, high efficiency, no continuous vibration effect, the EMPW has potential multi-layered aluminum (A1) tabs copper (Cu) busbar for lithium-ion batteries (LIBs). To further study impact I-shape coil width on dissimilar materials, a comprehensive experimental platform was established this work. The experiments three layers Al single Cu...