Manufacturing of hybrid aluminum copper joints by electromagnetic pulse welding – Identification of quantitative process windows

Psyk, Verena; Scheffler, Christian; Linnemann, Maik; Landgrebe, Dirk

doi:10.1063/1.5008128

Cited by 10 publications

(11 citation statements)

References 5 publications

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“…This means that especially for processes with small relative movement of coil and joining partners in-between two subsequent joining sequences, the available acceleration distance for the flyer is very small at the side facing the preceding welding sequence. Therefore, the collision velocity necessary for magnetic pulse welding cannot be reached as it is in the range of 300 m/s for this specific material combination, [8]. If the relative movement of tool coil and workpiece is sufficiently long so that the initial distance between flyer and target is approximately the same as in the first welding sequence, the acceleration is more effective.…”

Section: Fig 6 Exemplary Micrographs Of Welded and Non-welded Sectionsmentioning

confidence: 99%

Section: Motivation and Principle Of Incremental Magnetic Pulse Weldingmentioning

confidence: 99%

“…However, it is well known that bothflyer and target -can undergo significant changes in thickness due to the impact and the corresponding severe plastic deformation of the joining partners, which seems to be an indispensable prerequisite for magnetic pulse welding. This in turn influences the thickness of the part produced by magnetic pulse welding [8]. The deformation and the resulting thickness of flyer and target significantly depend on density and strength ratio of the joining partners.…”

Section: Thickness Of the Welded Specimensmentioning

confidence: 99%

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Incremental magnetic pulse welding of dissimilar sheet metals

et al. 2018

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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 easily reach several hundred millimetres in length, but only a few millimetres in width. If a larger connected area is required, incremental or sequential magnetic pulse welding is a promising alternative. Here, the inductor is moved relative to the joining partners after the first weld sequence and then another welding process is initiated. Thus, the welded area is extended gradually by arranging multiple adjacent weld seams. This paper demonstrates the feasibility of incremental magnetic pulse welding. Furthermore, the influence of important process parameters on the component quality is investigated and evaluated in terms of geometry and micrographic analysis. Moreover, the suitability of different mechanical testing methods is discussed for determining the strength of the individual weld seams.

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Section: Fig 6 Exemplary Micrographs Of Welded and Non-welded Sectionsmentioning

confidence: 99%

Section: Motivation and Principle Of Incremental Magnetic Pulse Weldingmentioning

confidence: 99%

Section: Thickness Of the Welded Specimensmentioning

confidence: 99%

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Incremental magnetic pulse welding of dissimilar sheet metals

et al. 2018

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“…However, it is well known that both flyer and target can undergo significant changes in thickness due to the impact and the corresponding severe plastic deformation of the joining partners, which seems to be an indispensable prerequisite for magnetic pulse welding. This in turn influences the thickness of the part produced by magnetic pulse welding [9]. The deformation and the resulting thickness of flyer and target significantly depend on the density and strength ratio of the joining partners.…”

Section: Thickness Of the Welded Specimensmentioning

confidence: 99%

“…1). In addition, feasibility was verified for material combinations which are of special interest for applications related to electrical engineering or heat transfer and conduction such as aluminium and copper [9]. Figure 1 shows examples of joints produced by magnetic pulse welding of similar and dissimilar sheet metals at Fraunhofer IWU.…”

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Experimental and numerical analysis of incremental magnetic pulse welding of dissimilar sheet metals

Psyk¹,

Linnemann²,

Scheffler³

2019

Manufacturing Rev.

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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.

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