Pulsed‐Magnetic Hot Joining ‐ New Solutions for Modern Lightweight Structures

Abstract

To further significantly reduce the car weight, new and innovative production technologies are necessary which allow to join aluminium and – in the future – magnesium profiles. Then it will be possible to connect components made of aluminium or magnesium base alloy with steel parts to one group. Such a new technology is pulsed‐magnetic joining. In order to lower the process forces necessary for pulsed‐magnetic joining of high strength aluminium alloys and in order to establish a technologically useful forming of magnesium alloys, joining at increased temperatures appears to be a viable solution. As part of the research a tool for pulsed‐magnetic hot joining has been developed that combines the processes of heating by induction and pulsed‐magnetic joining. The applicability and the potentials of the tool have been demonstrated with hot joining of aluminium and magnesium profiles. The combination of the techniques allows for the first time to join magnesium profiles with forming by using pulsed‐magnetic forming at high temperatures. Regarding aluminium the combination of the techniques allows a significant reduction of the magnetic pressure that is necessary for the forming process; it thereby increases the operating life of the tools.

Application of high velocity impact welding at varied different length scales

“…Hokari et al (1998) welded aluminum tube to copper tube, Aizawa et al (2007) welded aluminum alloys to carbon steel sheet, Ben-Artzy et al (2008) welded aluminum to magnesium, Hutchinson et al (2009) welded copper plate to zirconium-based bulk metallic glass plate. MPW has seen limited, but rapidly growing industrial application (Pulsar (http://www.pulsar.co.il/news/?nid=14); Shribman and Gafri, 2001;Uhlmann et al, 2005). The commonly welded length scale for MPW ranges from a few millimeters to several centimeters.…”

A Uniform Pressure Electromagnetic Actuator for Forming Flat Sheets

“…Here induction heating will be added to this unconventional forming technique and this will enable the fabrication of very complex nominally flat magnesium components (such as personal electronics cases). Uhlmann and Hahn [66] have demonstrated a tool using the hybrid approach for Magnesium. The infrastructure developed here can be easily applied to joining of materials at elevated temperatures in subsequent programs.…”