Measurement and analysis technologies for magnetic pulse welding: established methods and new strategies

Bellmann, J.; Lueg‐Althoff, J.; Schulze, Sebastian; Gies, S.; Beyer, Eckhard; Tekkaya, A. Erman

doi:10.1007/s40436-016-0162-5

Cited by 27 publications

(25 citation statements)

References 24 publications

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“…During the process adjustment, the circumferential weld quality was verified by a manual peel test [1]. In order to identify the lower energy limit, the charging energy was gradually decreased after each successful weld until a non-weld was detected.…”

Section: Joining Setupmentioning

confidence: 99%

“…After overcoming the standoff between the two joining partners, the flyer collides with the stationary "parent" part at impact velocities of several hundred meters per second. Under adequate conditions, typically a flash occurs, which can be recorded and correlated with the welding result [1,2]. The flash accompanies the jetting effect, which cleans and activates the surfaces of the joining partners so that a weld can be established under the action of the prevalent high impact pressures.…”

Section: Introductionmentioning

confidence: 99%

“…For process monitoring, the newly presented optical technique based on the recording of the impact flash was used. This technology was developed and introduced by the authors [1] and was correlated with the charging energy for the present investigations. For each joining experiment, the flash appearance time was recorded with this tool in order to identify possible process disturbances.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Targeted Weld Seam Formation and Energy Reduction at Magnetic Pulse Welding (MPW)

Bellmann

Beyer

Lueg‐Althoff

et al. 2017

eBIS

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Magnetic pulse welding is based on the high velocity impact of two joining partners and a promising technology especially for the joining of dissimilar metallic components. Under proper conditions, a solid-state bond forms at the overlapping interface that is typically at least as strong as the weaker base material. However, high thermal and mechanical loads act on the tool coil and provoke a limited lifetime. Furthermore, the prevalent magnetic fields obstruct a comprehensive process monitoring with conventional means. In this manuscript, approaches for reducing the load on the tool coil without compromising the joint quality are presented. This is obtained by an adaption of the coil geometry and the application of a boundary layer on one of the joining partners. Moreover, a new measuring system taking advantage of the naturally occurring impact flash is evaluated and successfully applied for the process development and detection of process disturbances.

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Section: Joining Setupmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Targeted Weld Seam Formation and Energy Reduction at Magnetic Pulse Welding (MPW)

Bellmann

Beyer

Lueg‐Althoff

et al. 2017

eBIS

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show abstract

“…There are already some principles available for direct and indirect measurement of the relevant velocity components at the point of impact [5]. For example, electro conductive foils on the parent surface [6] or contact pins [7] may act as switches when they get hit by the flyer and generate certain on-off-signals that can be used for an analysis of the process sequence.…”

mentioning

confidence: 99%

“…For a detailed understanding of the process conditions and their targeted manipulation it is also necessary to measure the collision front velocity v c . In a first step, small bore holes were implemented in the parent part to detect the on-off light signal while the flyer passed over each hole [5]. This approach was difficult to apply for small parts.…”

mentioning

confidence: 99%

Measurement of Collision Conditions in Magnetic Pulse Welding Processes

Bellmann¹,

Beyer²,

Lueg‐Althoff³

et al. 2017

JPSA

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MPW (magnetic pulse welding) is a solid state joining technology that allows for the generation of strong metallic bonds, even between dissimilar metals. Due to the absence of external heat, critical intermetallic phases can largely be avoided. In this process, Lorentz forces are utilized for the rapid acceleration of at least one of the two metallic joining partners leading to the controlled high velocity impact between them. The measurement of the collision conditions and their targeted manipulation are the key factors of a successful process development. Optical measuring techniques are preferred, since they are not influenced by the prevalent strong magnetic field in the vicinity of the working coil. In this paper, the characteristic high velocity impact flash during MPW was monitored and evaluated using phototransistors in order to measure the time of the impact. The results are in good accordance with the established PDV (photon Doppler velocimetry) and show a good repeatability. Furthermore, the collision front velocity was investigated using adapted part geometries within a series of tests. This velocity component is one of the key parameters in MPW; its value decreases along the weld zone. With the help of this newly introduced measurement tool, the magnetic pressure distribution or the joining geometry can be adjusted more effectively.

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Effect of the wall thickness on the forming behavior and welding result during magnetic pulse welding

Bellmann

Lueg‐Althoff

Schulze

et al. 2019

Materialwissenschaft Werkst

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Magnetic pulse welding is a promising technology for the joining of dissimilar metals. Since the input of thermal energy is significantly reduced compared to conventional fusion welding technologies, critical intermetallic phases can largely be avoided. Therefore, proper collision conditions are necessary. Those require a careful adjustment of the energetic and geometric parameters at the impact welding setup. The thickness of the accelerated joining partner (flyer) determines the necessary energy input for a successful weld. However, at the same time, it has an effect on the weld formation. This study utilizes a novel optical measurement system to explain these findings and to gain insights into the forming behavior of the flyer parts. It is shown that the collision angle depends on the flyer tube thickness and, thus, directly has an effect on the welding result. Keywords: Magnetic pulse welding / dissimilar metal welding / wall thickness / welding window / collision conditions / solid state welding Das Magnetpulsschweißen ist eine vielversprechende Technologie zum Fügen von verschiedenartigen Metallen. Der thermische Energieeintrag ist im Vergleich zu konventionellen Schmelzschweißverfahren stark reduziert, wodurch kritische intermetallische Phasen vermieden werden. Um dieses Ergebnis zu erzielen, müssen geeignete Kollisionsbedingungen herrschen, was wiederum eine sorgfältige Einstellung der energetischen und geometrischen Randbedingungen innerhalb der Fügeanordnung erfordert. Beispielsweise bestimmt die Dicke des beschleunigten Fügepartners (Flyer) die notwendige Ladeenergie, gleichzeitig beeinflusst sie aber auch die Schweißnahtausbildung an sich. Um diese Beobachtungen zu erklären und Einblicke in das Umformverhalten des Flyers zu gewinnen, kommt in dieser Studie ein neuartiges optisches Messsystem zum Einsatz. Es wird gezeigt, dass der Kollisionswinkel von der Flyerwandstärke abhängt und damit einen direkten Einfluss auf das Schweißergebnis hat.

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Measurement and analysis technologies for magnetic pulse welding: established methods and new strategies

Cited by 27 publications

References 24 publications

Targeted Weld Seam Formation and Energy Reduction at Magnetic Pulse Welding (MPW)

Targeted Weld Seam Formation and Energy Reduction at Magnetic Pulse Welding (MPW)

Measurement of Collision Conditions in Magnetic Pulse Welding Processes

Effect of the wall thickness on the forming behavior and welding result during magnetic pulse welding

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