Coupled Electromagnetic–Structural Simulation of Magnetic Pulse Welding

Abstract

The present study deals with the coupled magnetic-structural analysis of magnetic pulse welding (MPW) process applied on a tubular workpiece. The study investigates the various criteria required for a successful weld between the mating members through a finite element model. The transient electromagnetic field phenomenon is coupled sequentially with mechanical phenomenon. The coupling between the magnetic field and the electrical circuit is formulated in the electromagnetic part of the model, whereas in the structural part, the impact velocities, the effective plastic strain and the shear stress induced in the workpiece are found from the numerical simulations. A viscoplastic material model with rate-dependent material properties is considered in the structural part. The effect of varying process parameters: input voltage and air gap between the two mating members on weld quality are computed through numerical simulations. Based on the results of the numerical simulations, an optimal weldability window is suggested.

Comprehensive Weldability Criterion for Magnetic Pulse Welding of Dissimilar Materials

“…Thus, the effective impact velocity (V I ) (i.e., impact velocity expected during the actual experiment) should be higher than the threshold impact velocity but remain lower than V D . A typical jet behavior establishes a steady-state wave pattern at intermediate velocities, and the maximum bond strength is obtained [42]. Because of these limitations, the effective impact velocity (V I ) is proposed as a weldability criterion.…”

“…The operational details of the FEM are presented in Table 3. For additional details on the FEM employed in this study, the authors' previous work can be referred to [42,43].…”

An Application of a Magnetic Impulse for the Bending of Metal Sheet Specimens

“…The efforts of the researcher have resulted in the performance of forming metal sheets in an open magnetic field, as well as experiments focusing on connecting pipes using a magnetic field [ 24 , 25 , 26 , 27 ]. The use of the magnetic phenomenon can also be found for the welding of metal materials by means of a magnetic impulse [ 28 , 29 ].…”