This paper investigated the effect of magnetic pulse welding (MPW) condition (welding power, surface scratches, and contamination) on the establishment of welding between aluminum and copper tubes, and the associated welding mechanisms. The results showed that higher applied power and surface scratches in tangential direction were in favor for good weld, and oil on the surface prevented welding. Direct evidences were obtained on local interface melting under a high welding power. CuAl intermetallics with different atomic ratios were identified by energy dispersion spectrum (EDS) chemical analysis and by microscratching test. The mechanisms of MPW and the process improvement were discussed.

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