On Additive Manufactured AlSi10Mg to Wrought AA6060-T6: Characterisation of Optimal- and High-Energy Magnetic Pulse Welding Conditions

This novel research aims to examine the macro and microstructural bonding region development during magnetic pulse welding (MPW) of dissimilar additive manufactured (AM) laser powder-bed fusion (L-PBF) AlSi10Mg rod and AA6060-T6 wrought tube, using both optimal- and high-energy welding conditions. For that purpose, various joint characterisation methods were applied. It is demonstrated that high-quality hermetic welds are achievable with adjusted MPW process parameters. The macroscale analysis has shown that the joint interfaces are deformed to a waveform shape; the interface is starting relatively planar, with waves forming and growing in the welding direction. The observed thickening of the flyer’s wall after welding is the result of its diametral inward deformation, taking place during the process. A slight increase in microhardness was adjacent to the faying interfaces; a higher increase was measured on the AlSi10Mg material side, while a smaller one was observed on the AA6060 side. Along the wavy interfaces, resolidified “pockets” of material or occasionally discontinuous short layers exhibiting different morphologies, were detected. The jet residues are typically located towards the end of the weld, confirming a temperature rise that exceeds the melting temperature of both alloys. Far from the weld zone, extremely thin-film deposits were clearly observed on the inner flyer surfaces. The formation of isolated Si particles and thin-film deposits may point out that the local increase in temperatures leads to melting or even evaporation vaporisation of superficial layers from the colliding parts. It is worth noting that this type of jet residue was discovered for the first time in the present research. The current research work is expected to provide an understanding of weld formation mechanisms of additively manufactured parts to conventional wrought parts conforming to existing wrought/wrought weld knowledge.

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Potentials of Pulse Magnetic Forming and Joining

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.907.349 ◽

2014 ◽

Vol 907 ◽

pp. 349-364 ◽

Cited By ~ 5

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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Magnetic pulse welding of aluminum to steel tubes using a field-shaper with multiple seams

Journal of Manufacturing Processes ◽

10.1016/j.jmapro.2021.03.037 ◽

2021 ◽

Vol 65 ◽

pp. 214-227

Author(s):

Ziqin Yan ◽

Ang Xiao ◽

Xiaohui Cui ◽

Yuanzheng Guo ◽

Yuhong Lin ◽

...

Keyword(s):

Magnetic Pulse ◽

Steel Tubes ◽

Magnetic Pulse Welding ◽

Pulse Welding

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On the complete interface development of Al/Cu magnetic pulse welding via experimental characterizations and multiphysics numerical simulations

Journal of Materials Processing Technology ◽

10.1016/j.jmatprotec.2021.117185 ◽

2021 ◽

Vol 296 ◽

pp. 117185

Author(s):

J.S. Li ◽

T. Sapanathan ◽

R.N. Raoelison ◽

Y.L. Hou ◽

A. Simar ◽

...

Keyword(s):

Numerical Simulations ◽

Magnetic Pulse ◽

Magnetic Pulse Welding ◽

Pulse Welding

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

Proceedings of the Institution of Mechanical Engineers Part B Journal of Engineering Manufacture ◽

10.1177/09544054211014846 ◽

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.

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