Analytical Estimation of Electromagnetic Pressure, Flyer Impact Velocity, and Welded Joint Length in Magnetic Pulse Welding

Abstract

Magnetic pulse welding involves the joining of two metallic parts in a solid state by the use of a short and intense electromagnetic impulses and the resulting impact between the parts. The coalesced interface undergoes visco-plastic deformation at a high strain rate and exhibits a wavy shape at a microscopic scale. A practical estimation of the electromagnetic pressure, impact velocity and welded joint length as a function of the process conditions and the electromagnetic coil geometry is required but currently not available. Three novel analytical relations for the estimation of the electromagnetic pressure, impact velocity, and welded joint length for magnetic pulse welding of tubes and sheets, are presented. These relations were developed systematically, following a dimensional analysis, and validated for a wide range of conditions from independent literature. The comparison of the analytically computed results and the corresponding values reported in the literature has illustrated that the proposed analytical relations can be used for the estimation of the electromagnetic pressure and impact velocity for the magnetic pulse welding of tubes and sheets with a good level of confidence. The analytically calculated results for the welded joint length show a little discrepancy with the corresponding experimentally measured values. Further investigations and more experimentally measured results are required to arrive at a more comprehensive analytical relation for the prediction of welded joint length.

Effect of interlayer thickness and gap distance on vaporizing foil actuator welding of 5A06 aluminium alloy and 321 stainless steel

“…High-velocity impact welding is a welding process that occurs in the solid-state, providing a viable solution for the joining of dissimilar materials [7][8][9][10]. In recent times, the utilisation of the vaporizing Foil Actuator has showcased its versatility as a tool for various metalworking applications, with one such application being impact welding of dissimilar materials.…”

Analysis and Design of a Pulsed Power Generator for a Low-Energy Magnetic Pulse Welding System

“…Research on the materials of various metals is being conducted as follows: an optimization study on the welding of sheet structures of alloy EN AW-5005A and alloy EN AW-6060 [5], an optimization study of actuator for Al tubular welding [6], a study on the spot structure welding and quality of Al and carbon fiber reinforced polymer (CFRP) [7], a study on the welding of Al and Ti in the plate structure [8], a study on the spot structure bonding of Al and Fe [9]. Studies on the internal shape of the joint are as follows: a study on the shape analysis of metal welded surface according to the power size and reaction part structure [10,11] and an analysis study on impact velocity of welded surfaces [12]. Also, as research on the structure of the reaction part, welding or optimization studies according to Electronics 2023, 12, 4921 2 of 11 the flat and tubular shapes are being conducted [13,14].…”

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