Magnetic Pulse Hybrid Joining of Polymer Composites to Metals

To lighten their vehicles, car manufacturers are inclined to substitute steel structures with aluminum alloys or composites parts. They are then faced with the constraints inherent to dissimilar (galvanized steel/aluminum) or hybrid (metal/composite) assemblies. Recent developments in magnetic pulse welding seems to offer a viable route. Very fast, this process can be robotized and generates a very localized heating system which limits the formation of intermetallic and damage the composite. Low energy consumption, without filler metal or smoke it is recognized as an environmentally friendly process. In this paper, electromagnetic pulse welding is exploited to assemble polymer composite to metals. Two techniques, a metallic insert in polymer composite or an external patch, have been tested with possible design considerations.

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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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Investigations on arc brazing for galvanized heavy steel plates in steel and shipbuilding

Welding in the World ◽

10.1007/s40194-021-01087-2 ◽

2021 ◽

Author(s):

Philipp Andreazza ◽

Andreas Gericke ◽

Knuth-Michael Henkel

Keyword(s):

Low Cost ◽

Thin Sheet ◽

Steel Structures ◽

Tensile Tests ◽

Fatigue Tests ◽

Steel Plates ◽

Galvanized Steel ◽

Filler Materials ◽

Static Tensile ◽

Brazed Joints

AbstractArc brazing with low-melting copper-based filler materials, which has long been established and standardized in the thin sheet sector, offers numerous advantages in the processing of predominantly electrolytically galvanized steel structures. In steel and shipbuilding, on the other hand, equipment parts made of thick steel sheets are hot-dip galvanized at low cost and with good corrosion-inhibiting properties. Quality welding of such constructions is not possible without special precautions such as removing the zinc layer and subsequent recoating. With regard to greater plate thicknesses, arc brazing was analyzed in these investigations as an alternative joining method with regard to its suitability for practical use. Within the scope of the investigations, CuSi3Mn, CuMn12Ni2, and four different aluminum bronzes were examined on different sheet surface conditions with regard to the geometrical and production parameters. This was carried out by build-up and connection brazing, executed as butt and cross joints. Quasi-static tensile tests and fatigue tests were used to assess the strength behavior. In addition, metallographic analyses are carried out as well as hardness tests. The suitability for multi-layer brazing and the tendency to distortion were also investigated, as well as the behavior of arc brazed joints under corrosive conditions.

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