Adhesively joining metals of dissimilar melting point represents one of the most sophisticated tasks in joining technique. However, due to light weight considerations this type of joint, for example the connection between an aluminum flange and a high strength steel crash element, is of prior interest. The electromagnetic pulse technology is a proven process to accomplish adhesive joints between tubes made of dissimilar metals. Recent developments of the technique now allow welding even dissimilar and similar sheet metals under industrial conditions. This paper details the underlying mechanisms and shows a variety of samples, depicting for the potential of this new process.

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Electromagnetic forming is one of the high- rate forming methods that are extensively used to form and join axisymmetric tubes and metal sheet. It is a high speed forming process using a pulsed magnetic field to form work pieces made of metals such as copper or aluminum alloys with high electrical conductivity. In this work, the experimental investigation and mathematical analysis of electromagnetic compression forming of aluminum alloy tubes AA6063 is studied. The aim of the work was to verify the results from MATLAB code with the experimental data. Experiments were conducted on aluminum alloy AA6063 tubes of outer diameter 40 mm and wall thickness of 2 mm with a nominal tensile strength of 214 MPa. The tube was compressed using 4 turn helical actuator discharge coil that can be energized up to 20 kJ. A study on the post forming characteristics hardness and on metallurgical effects were also carried out. The results of the mathematical analysis using MATLAB 2010 showed good correlation with experimental results.

Electromagnetic forming (EMF) is a high energy rate forming (HERF) process. It is a high speed forming process using a pulsed magnetic field to form work pieces made of metals such as copper or aluminum alloys with high electrical conductivity. The work piece to be deformed will be located within the effective area of the tool coil so that the resulting type of stress during the forming process is determined by the type of coil used and its arrangement as related to the component. Tubular or structural components can be narrowed by means of compression coils or widened by means of expansion coils, where as sheet metal can be deformed by flat coils. In this work, the experimental investigation and simulation of electromagnetic compression forming of aluminum alloy tubes is studied. The aim of the paper was to verify the results from Finite element methods with experimental data. Experiments were conducted on Tubes of outer diameter 40 mm and wall thickness of 2 mm with a nominal tensile strength of 214 MPa. The tube was compressed using a 4 turn helical actuator discharge that can be energied up to 20 kJ. A field shaper made of aluminum was used. A Maximum reduction of 15.85% in diameters were measured. The same problem was simulated in ANSYS using static coupled electromagnetic analysis. The results of the Simulation showed good correlation with experimental results.

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