Parameter Identification for Magnetic Pulse Welding Applications

Abstract:

Magnetic pulse welding (MPW) is a promising technology to join dissimilar metals and to produce multi-material structures, e.g. to fulfill lightweight requirements. During this impact welding process, proper collision conditions between both joining partners are essential for a sound weld formation. Controlling these conditions is difficult due to a huge number of influencing and interacting factors. Many of them are related to the pulse welding setup and the material properties of the moving part, the so-called flyer. In this paper, a new measurement system is applied that takes advantage of the high velocity impact flash. The flash is a side effect of the MPW process and its intensity depends on the impact velocity of the flyer. Thus, the intensity level can be used as a welding criterion. A procedure is described that enables the user to realize a fast parameter development with only a few experiments. The minimum energy level and the optimum distance between the parts to be joined can be identified. This is of importance since a low energy input decreases the thermal and mechanical shock loading on the tool coil and thus increases its lifetime. In a second step, the axial position of the flyer in the tool coil is adjusted to ensure a proper collision angle and a circumferential weld seam.

• Periodical: Key Engineering Materials (Volume 767)
• Pages: 431-438
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.767.431
• Online since: April 2018
• Authors: Joerg Bellmann, Joern Lueg-Althoff, Sebastian Schulze, Soeren Gies, Eckhard Beyer, A. Erman Tekkaya
• Keywords: Collision Conditions, Collision Front Velocity, Impact Velocity, Magnetic Pulse Welding, Process Development, Solid State Bonding

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