scholarly journals Influence of Copper Interlayers on the Magnetic Pulse Welding Process between Aluminum and Steel

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 868
Author(s):  
Joerg Bellmann ◽  
Kristina Roder ◽  
Martina Zimmermann ◽  
Eckhard Beyer ◽  
Lothar Kroll ◽  
...  
Keyword(s):  
Large Scale ◽  
Intermetallic Phase ◽  
Welding Process ◽  
Fusion Welding ◽  
Magnetic Pulse ◽  
Scale Production ◽  
Joint Formation ◽  
Magnetic Pulse Welding ◽  
Pulse Welding ◽  
Welding Processes

Magnetic pulse welding (MPW) is a promising joining technology for the large-scale production of dissimilar metallic joints. Although the heat input is comparatively low, the temporary occurrence of high temperatures in the joining gap was found to play an important role during the joint formation. It is possible that the melting or even the boiling temperature of the involved materials will be exceeded, and fusion welding will occur. The purpose of this study is to investigate the influence of target materials with different thermal properties on the joint formation and weld seam characteristic. Therefore, MPW between steel targets and aluminum flyers was performed with and without copper coatings on steel. The lower melting temperature of copper compared to steel had no significant effect on the appearance of the mixed zones in the interface and the amount of molten target material or aluminum, respectively. Nevertheless, the comparison of the higher impact energies showed, that the copper interlayer can lead to a decrease in the weld length or a degradation of the weld quality due to an extended intermetallic phase formation or cracks. This result is important for the parameter adjustment of magnetic pulse welding processes.

scholarly journals Magnetic Pulse Welding and Spot Welding with Improved Coil Efficiency—Application for Dissimilar Welding of Automotive Metal Alloys

2020 ◽  
Vol 4 (3) ◽  
pp. 69 ◽  
Author(s):  
Chady Khalil ◽  
Surendar Marya ◽  
Guillaume Racineux
Keyword(s):  
Life Cycle ◽  
Spot Welding ◽  
Mass Scale ◽  
Fusion Welding ◽  
Dissimilar Welding ◽  
Magnetic Pulse ◽  
Scale Production ◽  
Magnetic Pulse Welding ◽  
Multiple Materials ◽  
Pulse Welding

Lightweight structures in the automotive and transportation industry are increasingly researched. Multiple materials with tailored properties are integrated into structures via a large spectrum of joining techniques. Welding is a viable solution in mass scale production in an automotive sector still dominated by steels, although hybrid structures involving other materials like aluminum are becoming increasingly important. The welding of dissimilar metals is difficult if not impossible, due to their differential thermo mechanical properties along with the formation of intermetallic compounds, particularly when fusion welding is envisioned. Solid-state welding, as with magnetic pulse welding, is of particular interest due to its short processing cycles. However, electromagnetic pulse welding is constrained by the selection of processing parameters, particularly the coil design and its life cycle. This paper investigates two inductor designs, a linear (I) and O shape, for the joining of sheet metals involving aluminum and steels. The O shape inductor is found to be more efficient both with magnetic pulse (MPW) and magnetic pulse spot welding (MPSW) and offers a better life cycle. Both simulation and experimental mechanical tests are presented to support the effect of inductor design on the process performance.

scholarly journals Improving and monitoring the magnetic pulse welding process between dissimilar metals

2020 ◽  
Author(s):  
Joerg Bellmann ◽  
Sebastian Schettler ◽  
Sebastian Schulze ◽  
Markus Wagner ◽  
Jens Standfuss ◽  
...  
Keyword(s):  
Monitoring System ◽  
Process Monitoring ◽  
Light Emission ◽  
Welding Process ◽  
Fusion Welding ◽  
Dissimilar Metals ◽  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
Pulse Welding ◽  
Process Observation

Abstract Conventional fusion welding of dissimilar metals is often limited due to the different thermo-physical properties of the joining partners. In consequence, brittle intermetallic phases (IMC) can occur. Utilizing a pressure welding process like magnetic pulse welding (MPW) reduces the risk of IMCs significantly. Furthermore, this welding process has an outstanding short process duration in the range of a few microseconds, which makes it predestined for mass production. At the same time, this advantage challenges the process observation, inline-quality assurance hardware, and the design of the tool coils. The paper presents two strategies for reducing the energy input during MPW to increase the tool coil lifetime. The first approach, the introduction of a reactive nickel interlayer between steel and aluminum, leads to a significant welding energy reduction. Compared to aluminum samples joined by laser welding, the load-bearing capability of the resulting hybrid MPW driveshaft samples is higher in static torsion tests and similar in cyclic tests. The second approach is based on a novel process monitoring system that helps to analyze the characteristic light emission. The capability of the process monitoring system is presented on the example of a MPW-joined multimaterial part made of stainless steel, aluminum, and copper.

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 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.

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.

Modelling of Tubes Magnetic Pulse Welding

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.

scholarly journals Measurement of Collision Conditions in Magnetic Pulse Welding Processes

2017 ◽  
Vol 7 (4) ◽  
Author(s):  
Joerg Bellmann ◽  
Eckhard Beyer ◽  
Joern Lueg-Althoff ◽  
Soeren Gies ◽  
A. Erman Tekkaya ◽  
...  
Keyword(s):  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
Pulse Welding ◽  
Welding Processes

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.

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.

scholarly journals Magnetic pulse welding

2010 ◽  
Vol 1 (1) ◽  
pp. 21-28
Author(s):  
Jan Broeckhove ◽  
Len Willemsens ◽  
Koen Faes
Keyword(s):  
Construction Industry ◽  
Analytical Model ◽  
Welding Process ◽  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
Master Thesis ◽  
Rapid Pace ◽  
Pulse Welding

The contemporary construction industry is evolving with a rapid pace and is pushing technological boundaries. Together with that progress new requirements on joints and joining techniques are imposed. This paper describes our research concerning an advanced joining technique, the Magnetic Pulse Welding process (MPW).The first part of this article briefly describes the MPW process and summarizes the differences with respect to conservative welding techniques. Secondly an analytical model of the process will be investigated on accuracy. This model was developed by the manufacturer of the MPW machine used at the Belgian Welding Institute. Further a description is given of the methods which are used to investigate the experimental joints. After describing the recently performed experiments, finally an overview will be given depicting the work that will be carried out during the rest of this master thesis

Sign in / Sign up

Export Citation Format

Share Document