Magnetic pulse welding (MPW) provides an efficient route to join overlapping metallic tubes by the application of a high magnitude electromagnetic (EM) force. The process is rapidly transient in nature with little scope to comprehend and monitor the evolution of the joint by experimental means. A comprehensive computational process model is presented here to analyse the transient nature of EM field and force, and resulting impact and plastic deformation during MPW of metallic tubes. The computed results are validated with the corresponding experimentally measured weld joint length for specific tube joint geometries. The computed values of the plastic deformation, impact angle and impact velocity along the joint interface are examined further to realise the progressive nature of the joint formation.
Lueg-AlthoffJ, SchillingB, BellmannJ, Influence of the wall thickness on the joint quality during magnetic pulse welding in tube-to-tube configuration. Conf High Speed Form. 2016; 7:259–268.
2.
ShimJY, KimIS, LeeKJ, Experimental and numerical analysis on aluminum/steel pipe using magnetic pulse welding. Metall Material Int. 2011; 17(6):957–961. doi: 10.1007/s12540-011-6014-8
3.
MishraS, SharmaSK, KumarS, 40 kj magnetic pulse welding system for expansion welding of aluminium 6061 tube. J Mater Process Technol2017; 240:168–175. doi: 10.1016/j.jmatprotec.2016.09.020
4.
ElsenA, LudwigM, SchaeferR, Fundamentals of EMPT welding. Conf High Speed Form. 2010; 4:117–126.
5.
KumarR, DoleyJ, KoreS.Finite element modelling and analysis of electromagnetic pulse welding of aluminium tubes to steel bar. Am Inst Phys. 2016; 10:1–6.
6.
CuiJ, SunG, XuJ, A study on the critical wall thickness of the inner tube for magnetic pulse welding of tubular Al-Fe parts. J Mater Process Technol2016; 227:138–146. doi: 10.1016/j.jmatprotec.2015.08.008
7.
LorenzA, Lueg-AlthoffJ, BellmannJ, Workpiece positioning during magnetic pulse welding of aluminium-steel joints. Weld Res. 2016; 95:101–106.
8.
NassiriA, CampbellC, ChiniG, Analytical model and experimental validation of single turn, axi-symmetric coil for electromagnetic forming and welding. Procedia Manuf. 2015; 1:814–827. doi: 10.1016/j.promfg.2015.09.070
9.
FanZ, YuH, LiC.Plastic deformation behaviour of bi-metal tubes during magnetic pulse cladding: FE analysis and experiments. J Mater Process Technol2016; 229:230–243. doi: 10.1016/j.jmatprotec.2015.09.021
10.
GuiglielmettiA, BurionN, MarceauD, Modelling of tubes magnetic pulse welding. Conf Eng Syst Des Anal. 2012; 11:1–12.
11.
PsykV, SchefflerC, LinnemannM, Process analysis for magnetic pulse welding of similar and dissimilar material sheet metal joints. Procedia Eng. 2017; 207:353–358. doi: 10.1016/j.proeng.2017.10.787
12.
PereiraD, OliveiraJP, PardalT, Magnetic pulse welding: machine optimisation for aluminium tubular joints production. Sci Technol Weld Join. 2017; 23:1–8.
13.
XuW, SunX.Numerical investigation of electromagnetic pulse welded interfaces between dissimilar metals. Sci Technol Weld Join. 2016; 21(7):592–599. doi: 10.1179/1362171815Y.0000000092
14.
UhlmannE, PrasolL, ZiefleA.Potentials of pulse magnetic forming and joining. Adv Mat Res. 2014; 907:349–364.
15.
KimchiM, ShaoH, ChengW, Magnetic pulse welding aluminium tubes to steel bars. Weld World. 2004; 48:19–22. doi: 10.1007/BF03266422
16.
ChariMVK, SalonSJ.Numerical method in electromagnetic. San Diego: Academic Press; 2000. p. 1–60. ISBN: 0-12-615760-X.
17.
SadikuMNO, KulkarniSV.Principle of Electromagnetics. 6th Edition. New Delhi, India: Oxford University Press; 2015. p. 383–480.
Ben-ArtzyA, SternA, FrageN, Wave formation mechanism in magnetic pulse welding. Int J Impact Eng. 2010; 37:397–404. doi: 10.1016/j.ijimpeng.2009.07.008
20.
Lueg-AlthoffJ, BellmanJ, GiesS, Influence of the flyer kinetics on magnetic pulse welding of tubes. J Mater Process Technol2018; 262:189–203. doi: 10.1016/j.jmatprotec.2018.06.005
21.
CrosslandB.Explosive welding of metals and its application. Oxford: Clarendon Press; 1982. p. 10–84. ISBN: 0-19-859119-5.
22.
YuanX, WangW, CaoX, Numerical study on the interfacial behaviour of Mg/Al plate in explosive/impact welding. Sci Eng Compos Mater. 2017; 24(4):581–590. doi: 10.1515/secm-2015-0316
23.
ZhangY, BabuSS, ZhangP, Microstructure characterisation of magnetic pulse welded AA6061-T6 by electron backscattered diffraction. Sci Technol Weld Join. 2008; 13(5):467–471. doi: 10.1179/174329308X341915
24.
SchumacherE, RebesdorfA, BohmS.Influence of the jet velocity on the weld quality of magnetic pulse welded dissimilar sheet joints of aluminium and steel. Materialwiss. Werkstofftech. 2019; 50:965–973. doi: 10.1002/mawe.201900048
25.
SteinbergDJ, CochranSG, GuinanMW.A constitutive model for metals applicable at high strain rate. J Appl Phys1980; 51:1498–1504. doi: 10.1063/1.327799
