Electromagnetic welding (EMW) is a solid state impact welding technique which uses pulsed electromagnetic field for welding electrically conductive work pieces like aluminum. High velocity of impact created by the electromagnetic force causes the removal of oxide layer from the weld interface. A fully coupled numerical analysis, incorporating the equivalent electric circuit of EMW, electromagnetic field propagation, heat transfer, and dynamic elasto-plastic deformation, has been carried out using LS-DYNA EM module. The numerical simulation results for the EM weld feasibility, deformation pattern, temperature distribution and velocity of impact are reported here and corroborated with the previously published literature. It is observed that the temperature rise is not significant to cause the melting of Al sheets indicating there will not be any intermetallics. Hence, present paper is important for welding dissimilar metals for automobile components. Metallographic studies have also revealed absence of any coarse or columnar grain structures at the weld interface.
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