Fatigue behavior of Al-CFRP spot-welded joints prepared by electromagnetic pulse welding

In this study, the fatigue performance of magnetic pulse welding (MPW) joints of AA5052 aluminum alloy and T300 carbon fiber reinforced polymer (CFRP) with sandwich structure was systematically investigated. Mechanical property tests and microscopic observations were used to evaluate joint performance and damage to the CFRP. The results showed that satisfactory tensile strength (up to 92.24% of the tensile strength of the base material) was obtained by optimization of discharge energy. However, the samples in the fatigue test exhibited more sensitive properties to the fatigue environment. The higher fatigue cycle life was demonstrated only when the stress amplitude Sa & LE; 20.41 MPa. The fatigue test data were analyzed by Weibull distribution to fit the S-N curves under different reliability levels, which can be used for reliability assessment and life prediction in practical applications. The CFRP surfaces in different states were studied by scanning electron microscope (SEM). It was found that MPW would not damage the surfaces, while delamination and cracking would gradually occur during the fatigue process.