Numerical simulation and experimental investigation on thermal characteristics during induction diffusion welding of Cu/Al dissimilar metals

IF 5 2区工程技术 Q1 ENGINEERING, MECHANICAL

International Journal of Thermal Sciences Pub Date : 2025-09-23 DOI:10.1016/j.ijthermalsci.2025.110335

Kai Gao, Qingxuan Chen, Lingkuan Xuan, Hanfeng Deng

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引用次数: 0

Abstract

The quality of copper-aluminum welding has a crucial impact on the safety and reliability of power battery connection plates and busbars. A new welding method, Induction Diffusion Welding (IDW), was studied to investigate the effects of working condition parameters such as power supply variations on the welding process. Additionally, the spatial distribution of electromagnetic and temperature fields was analyzed. The research results indicate that the power output has the most significant impact on magnetic flux density. Increasing the power from 25 kW to 45 kW results in an accelerated decrease rate of about 35 % in magnetic flux density, with a final decrease of about 30 % in magnetic flux density value. An increase in power input and heating duration helps to increase the maximum temperature and improve temperature uniformity. Power supply is a key factor determining the rate of temperature rise and temperature stabilization time. At 35 kW, the balance between heat generation and heat dissipation results in the shortest temperature stabilization period and the smallest cross-layer temperature gradient, with uniformity reaching a maximum of 97 %, an increase of 6.08 % and 1.32 % compared to 25 kW and 45 kW, respectively. The simulated maximum temperature variation and heat-affected zone distribution are in excellent agreement with experimental observations, thus verifying the accuracy and feasibility of the simulation model.

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铜/铝异种金属感应扩散焊接热特性的数值模拟与实验研究

铜铝焊接的质量对动力电池连接板和母线的安全性和可靠性有着至关重要的影响。研究了一种新的焊接方法——感应扩散焊（IDW），研究了电源等工况参数对焊接过程的影响。此外，还分析了电磁场和温度场的空间分布。研究结果表明，输出功率对磁通密度的影响最为显著。将功率从25kw增加到45kw，磁通密度加速下降约35%，最终磁通密度值下降约30%。增加输入功率和加热时间，可以提高最高温度，改善温度均匀性。电源是决定温升速率和稳温时间的关键因素。在35 kW时，产生和散热平衡，温度稳定周期最短，层间温度梯度最小，均匀性达到97%，比25 kW和45 kW分别提高了6.08%和1.32%。模拟的最高温度变化和热影响区分布与实验观测结果吻合良好，验证了模拟模型的准确性和可行性。

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来源期刊

International Journal of Thermal Sciences 工程技术-工程：机械

CiteScore

8.10

自引率

11.10%

发文量

531

审稿时长

55 days

期刊介绍： The International Journal of Thermal Sciences is a journal devoted to the publication of fundamental studies on the physics of transfer processes in general, with an emphasis on thermal aspects and also applied research on various processes, energy systems and the environment. Articles are published in English and French, and are subject to peer review. The fundamental subjects considered within the scope of the journal are: * Heat and relevant mass transfer at all scales (nano, micro and macro) and in all types of material (heterogeneous, composites, biological,...) and fluid flow * Forced, natural or mixed convection in reactive or non-reactive media * Single or multi–phase fluid flow with or without phase change * Near–and far–field radiative heat transfer * Combined modes of heat transfer in complex systems (for example, plasmas, biological, geological,...) * Multiscale modelling The applied research topics include: * Heat exchangers, heat pipes, cooling processes * Transport phenomena taking place in industrial processes (chemical, food and agricultural, metallurgical, space and aeronautical, automobile industries) * Nano–and micro–technology for energy, space, biosystems and devices * Heat transport analysis in advanced systems * Impact of energy–related processes on environment, and emerging energy systems The study of thermophysical properties of materials and fluids, thermal measurement techniques, inverse methods, and the developments of experimental methods are within the scope of the International Journal of Thermal Sciences which also covers the modelling, and numerical methods applied to thermal transfer.