scholarly journals Incremental magnetic pulse welding of dissimilar sheet metals

2018 ◽  
Vol 190 ◽  
pp. 02004
Author(s):  
Verena Psyk ◽  
Maik Linnemann ◽  
Christian Scheffler ◽  
Petr Kurka ◽  
Dirk Landgrebe
Keyword(s):  
High Speed ◽  
Welding Process ◽  
Magnetic Pulse ◽  
Pulsed Magnetic Fields ◽  
Promising Alternative ◽  
Magnetic Pulse Welding ◽  
Connected Area ◽  
Pulse Welding ◽  
The Individual ◽  
Weld Seams

Magnetic pulse welding is a solid state welding process using pulsed magnetic fields resulting from a sudden discharge of a capacitor battery through a tool coil in order to cause a high-speed collision of two metallic components, thus producing an impact-welded joint. The joint is formed at room temperature. Consequently, temperature-induced problems are avoided and this technology enables the use of material combinations, which are usually considered to be non-weldable. The extension of the typically linear weld seam can easily reach several hundred millimetres in length, but only a few millimetres in width. If a larger connected area is required, incremental or sequential magnetic pulse welding is a promising alternative. Here, the inductor is moved relative to the joining partners after the first weld sequence and then another welding process is initiated. Thus, the welded area is extended gradually by arranging multiple adjacent weld seams. This paper demonstrates the feasibility of incremental magnetic pulse welding. Furthermore, the influence of important process parameters on the component quality is investigated and evaluated in terms of geometry and micrographic analysis. Moreover, the suitability of different mechanical testing methods is discussed for determining the strength of the individual weld seams.

scholarly journals Experimental and numerical analysis of incremental magnetic pulse welding of dissimilar sheet metals

2019 ◽  
Vol 6 ◽  
pp. 7
Author(s):  
Verena Psyk ◽  
Maik Linnemann ◽  
Christian Scheffler
Keyword(s):  
High Speed ◽  
Welding Process ◽  
Deep Understanding ◽  
Magnetic Pulse ◽  
Pulsed Magnetic Fields ◽  
Promising Alternative ◽  
Magnetic Pulse Welding ◽  
Pulse Welding ◽  
The Individual ◽  
Weld Seams

Magnetic pulse welding is a solid-state welding process using pulsed magnetic fields resulting from a sudden discharge of a capacitor battery through a tool coil in order to cause a high-speed collision of two metallic components, thus producing an impact-welded joint. The joint is formed at room temperature. Consequently, temperature-induced problems are avoided and this technology enables the use of material combinations, which are usually considered to be non-weldable. The extension of the typically linear weld seam can reach several hundred millimetres in length, but only a few millimetres in width. Incremental or sequential magnetic pulse welding is a promising alternative to obtain larger connected areas. Here, the inductor is moved relative to the joining partners after the weld sequence and then another welding process is initiated. Thus, the welded area is extended by arranging multiple adjacent weld seams. This article demonstrates the feasibility of incremental magnetic pulse welding. Furthermore, the influence of important process parameters on the component quality is investigated and evaluated. The suitability of different mechanical testing methods for determining the strength of the individual weld seams is discussed. The results of numerical simulation are consulted in order to obtain deep understanding of the observed effects.

Experimental investigation and optimization on field shaper structure parameters in magnetic pulse welding

2021 ◽  
pp. 095440542110148
Author(s):  
Yingzi Chen ◽  
Zhiyuan Yang ◽  
Wenxiong Peng ◽  
Huaiqing Zhang
Keyword(s):  
Magnetic Field ◽  
High Speed ◽  
Light Metal ◽  
Magnetic Pulse ◽  
Cross Sectional ◽  
Magnetic Pulse Welding ◽  
Pulse Welding ◽  
Sectional Shape ◽  
Welding System ◽  
The Magnetic Field

Magnetic pulse welding is a high-speed welding technology, which is suitable for welding light metal materials. In the magnetic pulse welding system, the field shaper can increase the service life of the coil and contribute to concentrating the magnetic field in the welding area. Therefore, optimizing the structure of the field shaper can effectively improve the efficiency of the system. This paper analyzed the influence of cross-sectional shape and inner angle of the field shaper on the ability of concentrating magnetic field via COMSOL software. The structural strength of various field shapers was also analyzed in ABAQUS. Simulation results show that the inner edge of the field shaper directly affects the deformation and welding effect of the tube. So, a new shape of field shaper was proposed and the experimental results prove that the new field shaper has better performance than the conventional field shaper.

scholarly journals Magnetic Field Measurements during Magnetic Pulse Welding Using CMR-B-Scalar Sensors

Sensors ◽  
2020 ◽  
Vol 20 (20) ◽  
pp. 5925
Author(s):  
Voitech Stankevic ◽  
Joern Lueg-Althoff ◽  
Marlon Hahn ◽  
A. Erman Tekkaya ◽  
Nerija Zurauskiene ◽  
...  
Keyword(s):  
Magnetic Field ◽  
Colossal Magnetoresistance ◽  
Welding Process ◽  
Nondestructive Method ◽  
Magnetic Field Measurement ◽  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
Pulse Welding ◽  
The Magnetic Field

The possibility of applying CMR-B-scalar sensors made from thin manganite films exhibiting the colossal magnetoresistance effect as a fast-nondestructive method for the evaluation of the quality of the magnetic pulse welding (MPW) process is investigated in this paper. This method based on magnetic field magnitude measurements in the vicinity of the tools and joining parts was tested during the electromagnetic compression and MPW of an aluminum flyer tube with a steel parent. The testing setup used for the investigation allowed the simultaneous measurement of the flyer displacement, its velocity, and the magnitude of the magnetic field close to the flyer. The experimental results and simulations showed that, during the welding of the aluminum tube with the steel parent, the maximum magnetic field in the gap between the field shaper and the flyer is achieved much earlier than the maximum of the current pulse of the coil and that the first half-wave pulse of the magnetic field has two peaks. It was also found that the time instant of the minimum between these peaks depends on the charging energy of the capacitors and is associated with the collision of the flyer with the parent. Together with the first peak maximum and its time-position, this characteristic could be an indication of the welding quality. These results were confirmed by simultaneous measurements of the flyer displacement and velocity, as well as a numerical simulation of the magnetic field dynamics. The relationship between the peculiarities of the magnetic field pulse and the quality of the welding process is discussed. It was demonstrated that the proposed method of magnetic field measurement during magnetic pulse welding in combination with subsequent peel testing could be used as a nondestructive method for the monitoring of the quality of the welding process.

Parameter Identification for Magnetic Pulse Welding Applications

2018 ◽  
Vol 767 ◽  
pp. 431-438 ◽  
Author(s):  
Joerg Bellmann ◽  
Joern Lueg-Althoff ◽  
Sebastian Schulze ◽  
Soeren Gies ◽  
Eckhard Beyer ◽  
...  
Keyword(s):  
Minimum Energy ◽  
Welding Process ◽  
Axial Position ◽  
Intensity Level ◽  
Magnetic Pulse ◽  
Mechanical Shock ◽  
Magnetic Pulse Welding ◽  
Impact Welding ◽  
Pulse Welding ◽  
The Impact

Magnetic pulse welding (MPW) is a promising technology to join dissimilar metals and to produce multi-material structures, e.g. to fulfill lightweight requirements. During this impact welding process, proper collision conditions between both joining partners are essential for a sound weld formation. Controlling these conditions is difficult due to a huge number of influencing and interacting factors. Many of them are related to the pulse welding setup and the material properties of the moving part, the so-called flyer. In this paper, a new measurement system is applied that takes advantage of the high velocity impact flash. The flash is a side effect of the MPW process and its intensity depends on the impact velocity of the flyer. Thus, the intensity level can be used as a welding criterion. A procedure is described that enables the user to realize a fast parameter development with only a few experiments. The minimum energy level and the optimum distance between the parts to be joined can be identified. This is of importance since a low energy input decreases the thermal and mechanical shock loading on the tool coil and thus increases its lifetime. In a second step, the axial position of the flyer in the tool coil is adjusted to ensure a proper collision angle and a circumferential weld seam.

Comparison between Simple Seam Welding and Adjacent Parallel Seam Welding by Magnetic Pulse Sheet-Welding Method

2018 ◽  
Vol 910 ◽  
pp. 19-24
Author(s):  
Tomokatsu Aizawa ◽  
Kazuo Matsuzawa
Keyword(s):  
High Speed ◽  
Magnetic Pulse ◽  
Seam Welding ◽  
Magnetic Pulse Welding ◽  
Seam Weld ◽  
Small Cavity ◽  
Welding Method ◽  
Pulse Welding

This paper describes the comparison between simple seam welding and adjacent parallel seam welding by a magnetic pulse welding method for Al-Al sheets. In the case of the parallel seam welding, the sheets collided at high speed in two parallel along a narrow central part of a one-turn flat coil. The central part had two parallel upper parts. The width of the central part was same as that of the simple seam welding. The increase of the parallel seam-weld zones was more than double in total in comparison with the simple seam-weld zones. Two inside parallel seam-weld zones were connected each other with a small cavity.

Parallel Seam Welding of Aluminum Sheets by Magnetic Pulse Welding Method with Collision between Metal Jets

2013 ◽  
Vol 767 ◽  
pp. 171-176 ◽  
Author(s):  
Tomokatsu Aizawa ◽  
Kazuo Matsuzawa ◽  
Keigo Okagawa ◽  
Masaki Ishibashi
Keyword(s):  
Magnetic Flux ◽  
High Speed ◽  
Eddy Currents ◽  
Capacitor Bank ◽  
Magnetic Pulse ◽  
Experimental Conditions ◽  
Seam Welding ◽  
Magnetic Pulse Welding ◽  
Aluminum Sheets ◽  
Pulse Welding

This paper provides details about the adjacent parallel seam welding of a pair of aluminum sheets by a magnetic pulse welding (MPW) method. An impulse discharge current from a capacitor bank passes through a flat one-turn coil and concentrates on two parallel along the narrow middle parts of the coil. A magnetic flux is suddenly generated around the middle parts. This flux intersects the sheets which are overlapped on the middle parts. The resulting eddy currents are induced in the sheets, applying two parallel strong electromagnetic forces to them. The sheets having a gap collide with each other at high speed in two parallel. In this time, four metal jets occur just ahead of the collision front along the middle parts. Two metal jets occurring in the inside collide with each other if the experimental conditions are suitable.

Thermal Effect during Electromagnetic Pulse Welding Process

2016 ◽  
Vol 879 ◽  
pp. 1662-1667 ◽  
Author(s):  
Thaneshan Sapanathan ◽  
Kang Yang ◽  
Dmitrii Chernikov ◽  
Rija Nirina Raoelison ◽  
Vladimir Gluschenkov ◽  
...  
Keyword(s):  
Joule Heating ◽  
Eddy Current ◽  
High Speed ◽  
Heat Dissipation ◽  
Welding Process ◽  
Plastic Work ◽  
Magnetic Pulse ◽  
High Speed Impact ◽  
Pulse Welding ◽  
And Control

Magnetic pulse welding (MPW) is a solid state joining process, successfully utilized to join dissimilar metals. This advantage attracted manufacturing industries to fabricate hybrid materials to attain materials with a combination of multiple attributes. The high speed impact during the welding process causes various interfacial phenomena, which have been reported in previous research studies. Combined high speed collision, Joule heating due to eddy current and plastic heat dissipation cause noticeable heating in the workpiece. The heating from the plastic work and collision energy could particularly be significant at the vicinity of the interface compared to other regions of the workpiece. The Joule heating due to eddy current affects the entire workpiece that is prominent before the collision. There is a sharp increase of the temperature at the onset of weld formation due to dissipation of plastic work during the collision. 3D simulations of coupled electromagnetic-mechanical-thermal were carried out to investigate the heating due to the combined Joule heating and plastic dissipation. A case study of MPW, consist of a one turn coil combined with a field shaper, is used to investigate the welding process. The simulations were performed using LS-DYNA®, which has the capability of using both finite and boundary elements to solve the thermo-mechanical problem during electromagnetic forming. The predicted temperature distributions from numerical simulations show expected phenomena of Joule heating and plastic heat dissipation while the analytical approach used to estimate the localized increase in temperature due to supersonic gaseous compression. Minimizing the heating effect by identifying the influencing factors could help to optimize and control the quality of the magnetic pulse welded parts.

Effect of Process Parameters on Wavy Interfacial Morphology During Magnetic Pulse Welding

2020 ◽  
Vol 143 (1) ◽  
Author(s):  
Shunyi Zhang ◽  
Joern Lueg-Althoff ◽  
Marlon Hahn ◽  
A. Erman Tekkaya ◽  
Brad Kinsey
Keyword(s):  
Numerical Model ◽  
Impact Velocity ◽  
Thermal Analyses ◽  
Welding Process ◽  
Thick Target ◽  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
Interfacial Morphology ◽  
Pulse Welding ◽  
The Impact

Abstract Magnetic pulse welding (MPW) is a solid-state welding process that bonds similar and dissimilar metals using a high velocity collision. In this paper, effects of impact velocity, target tube thickness, and mandrel inclusion on the interfacial morphology were investigated through the welding of tubular parts, Al6060T4 (flyer) to Cu-ETP (target), by electromagnetic compression. The hypothesis tested in this research is that a “well-supported target,” i.e., either a thick target or the support of a mandrel, allows for vortices to be created at the interface during MPW provided that the impact velocity is sufficient. The mandrel used in the experiments was polyurethane with a Shore hardness of 92A, which was pre-stressed via a washer and nut. The impact velocity was measured via photon Doppler velocimetry (PDV) and used for the setup of numerical simulations. A 2D axisymmetric numerical model was implemented in LS-DYNA to predict the interfacial morphology. Thermal analyses in the numerical model were used to predict the local melting locations and compared with experimental observations. Both experimental and numerical results showed that the interfacial wavelength increased with an increase in the impact velocity and target thickness. Similarly, a thin target with mandrel support also caused an increase in the wavelength. Vortices were only generated with appropriate impact velocities and well-supported targets, i.e., again either a thick target or the support of a mandrel.

scholarly journals Magnetic pulse welding on the cutting edge of industrial applications

2014 ◽  
Vol 19 (1) ◽  
pp. 69-81 ◽  
Author(s):  
R. M. Miranda ◽  
B. Tomás ◽  
T. G. Santos ◽  
N. Fernandes
Keyword(s):  
Magnetic Field ◽  
Solid State ◽  
High Speed ◽  
Industrial Applications ◽  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
Advantages And Disadvantages ◽  
Pulse Welding ◽  
The Impact ◽  
Very High

Magnetic Pulse Welding (MPW) applies the electromagnetic principles postulated in the XIXth century and later demonstrated. In recent years the process has been developed to meet highly demanding market needs involving dissimilar material joining, specially involving difficult-to-weld materials. It is a very high speed joining process that uses an electromagnetic force to accelerate one material against the other, resulting in a solid state weld with no external heat source and no thermal distortions. A high power source, the capacitor, a discharge switch and a coil constitute the minimum equipment necessary for this process. A high intensity current flowing through a coil near an electrically conductive material, locally produce an intense magnetic field that generates eddy currents in the flyer according to Lenz law. The induced electromotive force gives rise to a current whose magnetic field opposes the original change in magnetic flux. The effect of this secondary current moving in the primary magnetic field is the generation of a Lorentz force, which accelerates the flyer at a very high speed. If a piece of material is placed in the trajectory of the flyer, the impact will produce an atomic bond in a solid state weld. This paper discusses the fundamentals of the process in terms of phenomenology and analytical modeling and numerical simulation. Recent industrial applications are presented in terms of materials, joint configurations and real examples as well as advantages and disadvantages of the process.

Potentials of Pulse Magnetic Forming and Joining

2014 ◽  
Vol 907 ◽  
pp. 349-364 ◽  
Author(s):  
Eckart Uhlmann ◽  
Lukas Prasol ◽  
Alexander Ziefle
Keyword(s):  
Magnesium Alloys ◽  
Metal Forming ◽  
High Speed ◽  
Weld Zone ◽  
Basic Research ◽  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
High Speed Forming ◽  
Pulse Welding ◽  
Welding Processes

Magnetic pulse production methods such as forming, joining or separating demonstrate innovative high-speed processes. Such processes can be realized using a capacitor and an appropriate tool coil for forming and welding processes. The process strain rates, which can amount to 20,000 s-1, increase the formability of metallic materials significantly. Magnesium and aluminium alloys find a wider application in the automotive industry due to their light weight potential. Through the low density of these materials, the vehicle weight can be reduced considerably. Due to the hexagonal lattice of magnesium alloys industry-relevant deformation in metal forming processes can only be achieved in hot forming processes. The high-speed forming allows a significant increase of deformability of this alloy. The use of dissimilar metals in an assembly requires the development of innovative joining methods. Apart from being used form and force closure the magnetic pulse welding and adhesive bonding material with different partners is possible. Currently at the Institute for Machine Tools and Factory Management (IWF), TU Berlin, various research topics in the field of pulsed magnetic are investigated. The magnetic pulse sheet metal forming of magnesium alloys at room temperature is investigated in a basic research project. A defined demarcation of high-speed forming with respect to the quasi-static deformation is done by means of hardness measurements in the deformation zone. For this purpose a suitable experimental setup with different matrices is constructed. The experimental results of the pulse magnetic deformation are iteratively compared with simulation results. The aim is to develop a new material model which gives a precise prediction about the high-speed process. In the field of magnetic pulse welding, both basic research and industry-related research projects conducted at the IWF. The process requires an adapted tool coil geometry that meets the requirements of the weld geometry. Different coil geometries and weld geometries and possible applications are presented by way of example, the welding quality is quantified by means of different analytical methods. The material microstructure in the weld zone, characterized by light and scanning electron microscopy shows the typical features of a shock welded joint, as also observed in explosive welding.

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