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In order to reduce CO2 emissions, an increasing interest in lightweight construction exists in the automotive industry, especially the multi-material-design approach. The main construction materials here are steels and aluminium alloys. Due to their different physical material properties and limited mutual solubility, these two materials cannot be joined thermally without difficulty. This paper presents a new joining approach for dissimilar materials. It uses electromagnetic displacement of a laser-generated melt pool to produce overlap joints between 1 mm steel (1.0330) and 2 mm aluminium alloy (EN AW 5754). Contactless induced Lorentz forces are generated by an alternating current (AC) magnet system. The controlled displacement of the aluminium alloy melt into the hole of the overlying steel sheet is investigated through numerical and experimental studies. The numerical results are compared with cross sections and thermocouple measurements. For the first time, it is possible to achieve a reproducible controlled melt pool displacement on thin sheets to produce overlap joints between dissimilar materials.
Fracture mechanics testing at dynamic loading conditions requires appropriate methods for the measurement of force and displacement. In some cases additional measurement techniques must be used to obtain further information like the time of crack initiation. Dedicated standard pro-cedures for impact type dynamic fracture mechanics tests are not available. Several standards on quasistatic or elevated loading rate fracture mechanics testing provide some more general experi-mental guidelines and they often exclude impact conditions. Therefore, the first step of dynamic fracture mechanics investigations should always be to establish an appropriate and validated test method.