scholarly journals Influence of process parameters on the weld quality of dissimilar Cu-Al magnetic pulse welded sheets

2016 ◽  
Vol 7 (1) ◽  
pp. 8 ◽  
Author(s):  
Wim Demonie ◽  
Koen Faes ◽  
Wim De Waele
Keyword(s):  
Design Method ◽  
Geometrical Parameters ◽  
Magnetic Pulse ◽  
Weld Quality ◽  
Influence Of Process Parameters ◽  
Free Length ◽  
Lap Shear ◽  
Experimental Design Method ◽  
Pulse Welding

Little is known about the influence of the main geometrical parameters (overlap, stand-off and free length) and the energy input on welds formed by electromagnetic pulse welding. The Taguchi experimental design method was applied for determining the underlying relations for dissimilar sheet welding of copper and aluminium. The weld quality was evaluated based on four output parameters: the weld length, the size of the interfacial layer, the lap shear strength and the thickness reduction of the flyer sheet. The influence of the overlap and free length showed to be non-negligible; this in contrast to the small amount of attention these parameters receive in other publications.

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.

scholarly journals Development Parameters of Pneumatic Slotted Sprayers for Treatment Potato Tubers

2019 ◽  
Vol 9 (2) ◽  
pp. 1200-1203
Keyword(s):  
Experimental Design ◽  
Design Method ◽  
Working Fluid ◽  
Potato Tubers ◽  
Flow Rates ◽  
Financial Costs ◽  
Experimental Design Method ◽  
Potato Planter ◽  
Spray Gun

This article presents the results of developing the design of the device and optimizing the parameters of the pneumatic slotted spray gun recommended for treating tubers with working fluids. In connection with the task, the flow rates of the working fluid by the sprayer were determined by the experimental design method and the speed characteristics of the airborne droplet for treating tubers in the coulters of a potato planter. It was found that the use of a device for processing tubers during the planting process contributes to the intensification of the cultivation of tubers while reducing financial costs and improving the quality of processing.

scholarly journals Studies of a Rotary–Centrifugal Grain Grinder Using a Multifactorial Experimental Design Method

2019 ◽  
Vol 11 (19) ◽  
pp. 5362 ◽  
Author(s):  
Marczuk ◽  
Blicharz-Kania ◽  
Savinykh ◽  
Isupov ◽  
Palichyn ◽  
...  
Keyword(s):  
Experimental Design ◽  
Design Method ◽  
Technical Condition ◽  
Technical Literature ◽  
Optimization Criteria ◽  
Impact Cutting ◽  
Experimental Design Method ◽  
Dust Fraction ◽  
Experimental Design Methodology

A scientific and technical literature review on machines designed to grind fodder grain revealed that the existing designs of grinding machines—those based on destruction by impact, cutting, or chipping—have various drawbacks. Some disadvantages include high metal and energy intensity, an uneven particle size distribution of the ground (crushed) product, a high percentage of dust fraction, the rapid wear of work tools (units), and heating of the product. To eliminate most of the identified shortcomings, the design of a rotary–centrifugal grain grinder is proposed in this paper. The optimization of the grinder’s working process was carried out using experimental design methodology. The following factors were studied: the grain material feed, rotor speed (rpm), opening of the separating surface, number of knives (blades) on the inner and outer rings, technical conditions of the knives (sharpened or unsharpened), and the presence of a special insert that is installed in the radial grooves of the distribution bowl. The optimization criteria were based on the amount of electricity consumed by and the performance of the rotary–centrifugal grain grinder. The quality of performance was quantified by the finished product, based on the percentage of particles larger than 3 mm in size. An analysis of the results of the multifactorial experiment allowed us to establish a relationship (interaction) between the factors and their influence on the optimization criteria, as well as to determine the most significant factors and to define further directions for the research of a centrifugal–rotary grain grinder. From our experimental results, we found that the grinder is underutilized in the selected range of factor variation. Furthermore, the number of knives installed at the second stage of the grinder, the gap (clearance) of the separating surface, and the technical condition of the knives are among the most important factors influencing the power consumption and the quality of the resulting product. A reduction in the number of knives at the first stage has a positive effect on all the selected optimization criteria; and by varying the factors in the selected range, it is possible to obtain a product corresponding to medium and coarse grinding.

scholarly journals Electromagnetic Pulse Welding of Tubular Products: Influence of Process Parameters and Workpiece Geometry on the Joint Characteristics and Investigation of Suitable Support Systems for the Target Tube

Metals ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 514 ◽  
Author(s):  
Koen Faes ◽  
Irene Kwee ◽  
Wim De Waele
Keyword(s):  
Electromagnetic Pulse ◽  
Support Systems ◽  
Cross Sectional Area ◽  
Second Phase ◽  
Weld Quality ◽  
Sectional Area ◽  
Cross Sectional ◽  
Influence Of Process Parameters ◽  
Joint Characteristics ◽  
Pulse Welding

In this experimental research, copper to steel tubular joints were produced by electromagnetic pulse welding. In a first phase, non-supported target tubes were used in order to investigate the influence of the workpiece geometry on the weld formation and joint characteristics. For this purpose, different joint configurations were used, more specific the tube-to-rod and the tube-to-tube configurations, with target workpieces with different diameters and wall thicknesses. Also, some preliminary investigations were performed to examine a support method for the target tubes. In a second phase, suitable support systems for the target tubes were identified. The resulting welds were evaluated in terms of their leak tightness, weld length and deformation of the target tube. It can be concluded that polyurethane (PU), polymethylmethacrylaat (PMMA), polyamide (PA6.6) and steel rods can be considered as valuable internal supports leading to high-quality welds and a sufficient cross-sectional area after welding. Welds with a steel bar support exhibit the highest cross-sectional area after welding, but at the same time the obtained weld quality is lower compared to welds with a PA6.6 or PMMA support. In contrast, welds with a PA6.6 or PU support show the highest weld quality, but also have a lower cross-sectional area after welding compared to steel internal supports.

scholarly journals Experimental and Numerical Investigations into Magnetic Pulse Welding of Aluminum Alloy 6016 to Hardened Steel 22MnB5

2021 ◽  
Vol 5 (3) ◽  
pp. 66
Author(s):  
Rico Drehmann ◽  
Christian Scheffler ◽  
Sven Winter ◽  
Verena Psyk ◽  
Verena Kräusel ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Base Material ◽  
Soft Materials ◽  
Lateral Position ◽  
Process Window ◽  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
Lap Shear ◽  
Pulse Welding ◽  
The Impact

By means of magnetic pulse welding (MPW), high-quality joints can be produced without some of the disadvantages of conventional welding, such as thermal softening, distortion, and other undesired temperature-induced effects. However, the range of materials that have successfully been joined by MPW is mainly limited to comparatively soft materials such as copper or aluminum. This paper presents an extensive experimental study leading to a process window for the successful MPW of aluminum alloy 6016 (AA6016) to hardened 22MnB5 steel sheets. This window is defined by the impact velocity and impact angle of the AA6016 flyer. These parameters, which are significantly dependent on the initial gap between flyer and target, the charging energy of the pulse power generator, and the lateral position of the flyer in relation to the inductor, were determined by a macroscopic coupled multiphysics simulation in LS-DYNA. The welded samples were mechanically characterized by lap shear tests. Furthermore, the bonding zone was analyzed by optical and scanning electron microscopy including energy-dispersive X-ray spectroscopy as well as nanoindentation. It was found that the samples exhibited a wavy interface and a transition zone consisting of Al-rich intermetallic phases. Samples with comparatively thin and therefore crack-free transition zones showed a 45% higher shear tensile strength resulting in failure in the aluminum base material.

Magnetic Pulse Welding by Electromagnetic Compression: Determination of the Impact Velocity

2014 ◽  
Vol 966-967 ◽  
pp. 489-499 ◽  
Author(s):  
Joern Lueg-Althoff ◽  
Amanda Lorenz ◽  
Soeren Gies ◽  
Christian Weddeling ◽  
Gunther Goebel ◽  
...  
Keyword(s):  
Impact Velocity ◽  
Measurement Data ◽  
Analytical Determination ◽  
Geometrical Parameters ◽  
Magnetic Pulse ◽  
Engineering Structures ◽  
Magnetic Pulse Welding ◽  
Pulse Welding ◽  
The Impact

The implementation of multi-material concepts and the manufacturing of modern lightweight structures, for example in automotive engineering, require appropriate joining technologies. The ability to join dissimilar materials without additional mechanical elements, chemical binders, or adverse influences of heat on the joining partners is key in reaching the desired weight reduction in engineering structures. The Magnetic Pulse Welding (MPW) process meets these demands, making it a viable alternative to conventional thermal welding and mechanical joining processes. The present paper focuses on the analytical determination of the impact velocity as one of the key parameters of MPW processes. On the basis of experimentally recorded data concerning the course of the discharge current and geometrical parameters of the welding setup, the respective velocity is determined. A comparison with measurement data gained by Photon Doppler Velocimetry is performed.

scholarly journals Investigation of the weldability of copper to steel tubes using the electromagnetic welding process

2017 ◽  
Vol 8 (1) ◽  
pp. 7
Author(s):  
Barbara Simoen ◽  
Koen Faes ◽  
Wim De Waele
Keyword(s):  
Radial Direction ◽  
Large Deformations ◽  
Welding Process ◽  
Steel Tube ◽  
Magnetic Pulse ◽  
Steel Tubes ◽  
Dissimilar Metal ◽  
Internal Support ◽  
Pulse Welding

Magnetic pulse welding is an innovative joining method which allows joining of dissimilar metal combinations. However, much remains unknown about the process and its parameters. In this paper, the weldability of copper tubes to steel rods and tubes is discussed, with the goal of examining the influence of the wall thickness of the supporting steel tube on the weld and the deformation of the components. Large deformations were observed, causing an undesirable decrease in diameter of the tubes. The quality of the obtained welds was shown to decrease with decreasing inner tube thickness as well, most likely due to the deformation of the workpieces in radial direction. Because of this, it is advisable to use an internal support to prevent deformation of the support tubes. To gain more insight in the precise mechanisms of weld formation and failure, numerical simulations are advised.

Magnetic Pulse Spot Welding: An Innovative Approach

2014 ◽  
Vol 922 ◽  
pp. 481-486
Author(s):  
Arun Prasath Manogaran ◽  
Prabu Manoharan ◽  
Didier Priem ◽  
Surendar Marya ◽  
Guillaume Racineux
Keyword(s):  
Spot Welding ◽  
Base Material ◽  
Tensile Tests ◽  
Air Gap ◽  
Innovative Approach ◽  
Magnetic Pulse ◽  
High Current ◽  
Pulse Welding ◽  
Very High

The magnetic pulse welding is a rapid process (takes place within few micro seconds) that joins both homogeneous and heterogeneous materials in the solid state. The process involves applying variable high current on an inductor to generate Lorentz forces on to the conductive primary part (flyer). To realize the weld it is necessary to accelerate the flyer to impact on to the secondary stationary part (base material) at a very high velocity attained over the distance, called air gap, between the parts. It is typically possible to perform welding of tubes and sheets provided there is an optimized air gap between the parts to be welded. As part of our work we have developed an innovative approach (Magnetic Pulse Spot Welding-MPSW) that eliminates the delicate task of maintaining the aforementioned air gap between the plates. The proposed method opens better viable perspectives for heterogeneous assembly of automotive structures or connecting batteries in a quasi-cold state. The developed approach has been validated on the heterogeneous assembly Al/Fe by tensile tests (quasi-static and dynamic) that attested the quality of welds.

Synergistic Analysis of Seawater Parameters’ Effect on Corrosion Rate of Austenitic Stainless Steels 304 and 316

2010 ◽  
Author(s):  
Mahmood Pakshir ◽  
Sanam Atashin ◽  
Arash Yazdani
Keyword(s):  
Corrosion Rate ◽  
Stainless Steels ◽  
Design Method ◽  
Austenitic Stainless Steels ◽  
Average Value ◽  
Experimental Design Method ◽  
Engineering Designs ◽  
Marine Engineering ◽  
The Individual

In this research the synergistic effect of environmental factors on corrosion rate of austenitic stainless steels 304 and 316 has been assessed. The behavior and resistance of these alloys are studied in aerated synthetic seawater, using potentiodynamic polarization scan. The salinity, velocity, pH and temperature are the considered parameters. To study the individual and interactive contribution percentage of parameters on changing the average value of corrosion rate, a quantitative full two-level factorial experimental design method is applied. Beside this quantitative analysis, qualitative analysis has been used to predict the variation direction. By means of these two analyses we can predict the magnitude and quality of each parameter’s effect. This research has a potential in prediction of alloys’ behavior, which is really valuable in marine engineering designs.

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