Development and calibration of a weldability window for Al-Ti composite by magnetic pulse welding

Current optimization of process parameters for aluminum/titanium magnetic pulse welding (MPW) relies heavily on extensive experimental trials and comparative analysis of joint mechanical properties – an approach that is not only energy-intensive but also destructive, resulting in significant material waste. To enhance research efficiency, there is a critical need for a low-cost, nondestructive method for process evaluation. The welding window concept offers a promising alternative for parameter optimization. In this study, a numerical model is developed to calibrate the welding window for Al/Ti MPW through integrated simulation and experimental analysis. The calibrated model enables accurate prediction of weld width and significantly improves the efficiency of process parameter selection, providing a theoretical foundation for quality assurance in dissimilar material welding.