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

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.

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

Sensors ◽

10.3390/s20205925 ◽

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.

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Modelling of Tubes Magnetic Pulse Welding

Volume 1: Advanced Computational Mechanics; Advanced Simulation-Based Engineering Sciences; Virtual and Augmented Reality; Applied Solid Mechanics and Material Processing; Dynamical Systems and Control ◽

10.1115/esda2012-82931 ◽

2012 ◽

Author(s):

A. Guglielmetti ◽

N. Buiron ◽

D. Marceau ◽

M. Rachik ◽

C. Volat

Keyword(s):

Magnetic Field ◽

Numerical Modeling ◽

Finite Elements ◽

Dynamical Model ◽

Magnetic Pulse ◽

Magnetic Pulse Welding ◽

Pulse Welding ◽

Welding Processes ◽

The Magnetic Field ◽

Mechanical Phenomena

Magnetic pulse process is used in the forming and welding processes. In order to predict the welding conditions, it is necessary to have an accurate modeling, which involves a coupling between magnetic and mechanical phenomena. In a first step, a numerical modeling of the magnetic field has been developed in the finite elements software ANSYS™, and the forces exerted on a tube have been predicted. The model has been validated by comparison with similar models. The influences of the different parameters have been studied. Then, the deformation of this tube has been predicted by a dynamical model in the finite elements software ABAQUS/Explicit™. As the tube shrinks, the mechanical and magnetic computings must be sequentially coupled in order to predict the forces exerted during the motion. Software MATLAB™ is used to couple the two models in the two softwares.

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Magnetic pulse welding on the cutting edge of industrial applications

Soldagem & Inspeção ◽

10.1590/s0104-92242014000100009 ◽

2014 ◽

Vol 19 (1) ◽

pp. 69-81 ◽

Cited By ~ 14

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.

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Influence of Cross-sectional Shape of Coil on Joining Property in Sheets Welded by Magnetic Pulse Welding

Journal of the Japan Society for Technology of Plasticity ◽

10.9773/sosei.61.226 ◽

2020 ◽

Vol 61 (718) ◽

pp. 226-231

Author(s):

Keigo OKAGAWA ◽

Masaki ISHIBASHI ◽

Shunichi KITTA ◽

Daisuke HIRUSAWA ◽

Takaomi ITOI

Keyword(s):

Magnetic Pulse ◽

Cross Sectional ◽

Magnetic Pulse Welding ◽

Pulse Welding ◽

Sectional Shape

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

Manufacturing Review ◽

10.1051/mfreview/2019007 ◽

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.

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

Materials Science Forum ◽

10.4028/www.scientific.net/msf.910.19 ◽

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.

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

Materials Science Forum ◽

10.4028/www.scientific.net/msf.767.171 ◽

2013 ◽

Vol 767 ◽

pp. 171-176 ◽

Cited By ~ 2

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.

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Axisymmetric control of large tokamak devices

Journal of Plasma Physics ◽

10.1017/s0022377800002166 ◽

1984 ◽

Vol 32 (3) ◽

pp. 399-412 ◽

Cited By ~ 2

Author(s):

T. H. Jensen ◽

F. W. McClain

Keyword(s):

Magnetic Field ◽

Control Problem ◽

Vacuum Chamber ◽

Practical Method ◽

Chamber Wall ◽

Power Supplies ◽

Cross Sectional ◽

Resistive Wall ◽

Sectional Shape ◽

The Magnetic Field

The problem of controlling the position and cross-sectional shape of plasmas is addressed for circumstances relevant to large tokamaks. A principle for, as well as a practical method of analysis of, this control problem is presented. The relevant elements of the tokamak system included in the analysis are the plasma, a resistive wall (vacuum chamber wall) surrounding the plasma, toroidally wound coils which also surround the plasma, as well as their associated external circuitry and a number of monitors of properties of the magnetic field in the vicinity of the plasma; the signals obtained from these monitors are used for control of power supplies which are part of the external circuits.

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