Advancement in high strain rate magnetic pulse joining of aluminum–alumina via numerical and experimental approach

Abstract

Ceramic-metal joints are crucial in structural applications across the aerospace, automotive, biomedical, and electronics industries due to their exceptional strength-to-weight ratios, superior corrosion resistance, and high-temperature stability. Magnetic Pulse Crimping (MPC) is a high-strain-rate joining technique that utilizes pulsed magnetic fields to apply Lorentz forces to workpieces, achieving joining through the forming of the workpieces. This manuscript examines the joining of AA 1050 aluminum tubes to alumina ceramic rods without generating heat-induced defects. Experiments were conducted at varying discharge energies, ranging from 1 to 6 kJ, using an Archimedean spiral coil and a step-taper field shaper to optimize joint strength. Irregular interfaces and localized unevenness were observed using SEM, specifically at the optimized discharge energy of 4 kJ, where joint strength was maximized. A coupled numerical investigation using the LS-DYNA EM module was employed to correlate the experimental findings. The parameters involved in the MPC, including current density, magnetic field, displacement, and impact velocity, were analyzed. Further, time step and mesh sensitivity analyses were performed to balance computational cost and simulation efficiency. This work demonstrates a new approach for robust ceramic-metal joining and interfacial bonding using MPC. Simultaneously, it provides a fundamental understanding of high strain rate deformation mechanisms in metal-ceramic systems, offering practical insights for industries that prioritize lightweight, high-performance hybrid structures. © IMechE 2026