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<p>A novel constricted micro gas tungsten arc (GTA) joining process was developed to manufacture a lap joint of Al and Cu foils, and suppress the defect formation. A multi-physical model was built and validated to investigate the temperature and fluid flow fields, and dissimilar element mixing in micro GTA lap joining. The Marangoni stress was found to be the dominant driving force for the molten pool convection, but the flow patterns were different from conventional Marangoni flow, because the Cu content had a more important role on the surface tension than the temperature. On the top surface, the molten metal flowed backward to the rear part of the molten pool, and then flowed inward and downward to the bottom, transporting a large amount of Al element to the bottom. On the bottom surface, the Cu content and the surface tension in the rear part were low, causing the molten metal to flow forward. The Cu in the front part flowed upward, increasing the Cu content in the top region.</p>

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Element mixing in micro GTA lap joining of Al and Cu foils

  • 期刊论文

  • 发表日期：

    2025年3月7日

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  • Dongsheng Wu,
  • Hisaya Komen,
  • Yuki Asai,
  • Manabu Tanaka,
  • Tadasuke Murata,
  • Akihisa Murata

摘要

A novel constricted micro gas tungsten arc (GTA) joining process was developed to manufacture a lap joint of Al and Cu foils, and suppress the defect formation. A multi-physical model was built and validated to investigate the temperature and fluid flow fields, and dissimilar element mixing in micro GTA lap joining. The Marangoni stress was found to be the dominant driving force for the molten pool convection, but the flow patterns were different from conventional Marangoni flow, because the Cu content had a more important role on the surface tension than the temperature. On the top surface, the molten metal flowed backward to the rear part of the molten pool, and then flowed inward and downward to the bottom, transporting a large amount of Al element to the bottom. On the bottom surface, the Cu content and the surface tension in the rear part were low, causing the molten metal to flow forward. The Cu in the front part flowed upward, increasing the Cu content in the top region.