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.

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.

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.

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 Magnetic pulse welding on the cutting edge of industrial applications

2014 ◽  
Vol 19 (1) ◽  
pp. 69-81 ◽  
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.

Welding Interface in Magnetic Pulse Welded Joints

2010 ◽  
Vol 654-656 ◽  
pp. 755-758 ◽  
Author(s):  
Mitsuhiro Watanabe ◽  
Shinji Kumai
Keyword(s):  
Explosive Welding ◽  
Intermediate Phase ◽  
Dissimilar Materials ◽  
Magnetic Pulse ◽  
Fine Crystal ◽  
Phase Layer ◽  
Magnetic Pulse Welding ◽  
Welding Interface ◽  
Pulse Welding ◽  
The Impact

Magnetic pulse welding was applied to the lap joining of similar (Al/Al) and dissimilar materials (Al/Fe, Al/Cu, and Al/Ni). The magnetic pulse welding is a kind of impact welding represented by explosive welding. The impact energy is induced by electromagnetic force generated by interaction among discharge pulse, induced magnetic flux, and eddy current produced at the plate surface. The welding was achieved within 10 microseconds with a negligible temperature increase. The welding interface exhibited a characteristic wavy morphology, which was similar to that of the explosive welding. In the Al/Fe, Al/Cu, and Al/Ni joints, an intermediate phase layer was produced along the wavy interface. In order to investigate microstructure of the intermediate phase layer, TEM observation of the welding interface was carried out. TEM observation revealed that the intermediate phase layer consisted of amorphous phase and fine crystal grains.

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

scholarly journals Experimental study on the magnetic pulse welding process of large aluminum tubes on steel rods

2019 ◽  
Vol 480 ◽  
pp. 012033 ◽  
Author(s):  
J Bellmann ◽  
S Schettler ◽  
S Dittrich ◽  
J Lueg-Althoff ◽  
S Schulze ◽  
...  
Keyword(s):  
Experimental Study ◽  
Welding Process ◽  
Magnetic Pulse ◽  
Magnetic Pulse Welding ◽  
Aluminum Tubes ◽  
Pulse Welding

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.

Sign in / Sign up

Export Citation Format

Share Document