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Feasibility of electromagnetic welding of flat sheets is ascertained by comparing the minimum impact velocities determined by using software ANSYS/EMAG and ABAQUS with the required minimum velocity obtained from analytical considerations. Magnetic forces acting on the sheets are computed from ANSYS/EMAG simulations. The velocity of impact and the pressure profile acting on the sheets are found from ABAQUS simulations. A criterion for weld formation is subsequently arrived at based on the simulations, which is further validated using experimental results. The reasons for no-weld zone in Al-to-Al EM weld and complete metal continuity (absence of no-weld zone) in Al-to-SS EM weld have been analyzed based on the numerical and experimental results.

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