Magnetic pulse welding can be considered as an advanced joining technique because it does not require any shielding atmosphere and input heat similar to conventional welding techniques. However, it requires comprehensive evaluations for bonding dissimilar materials. In addition to processing parameters, the surface preparation of the components, such as target material, needs to be evaluated. Different surface conditions were tested (machined, sand-blasted, polished, lubricated, chemically attacked, and threaded) using a fixed gap and standoff distance for welding. Microstructural observations and tensile testing revealed that the weld quality is dependent on surface preparation. The formation of waviness microstructure and intermetallic compounds were verified at the interface of some joints. However, these conditions did not guarantee the strength.
In the present paper, an EMF numerical model has been developed following an uncoupled approach, being the Lorentz forces acting on the workpiece estimated by solving Maxwells equations and then transferred to solve the mechanical problem. For formability analysis, a fracture indicator based on the linear forming limit diagram was applied through the use of a post-processing tool developed by the authors. To illustrate the applicability of the implemented code in the fracture prediction, an example of electromagnetic tube expansion is presented. The corresponding numerical simulation is performed and its results are compared with experimental obtained from literature for a selected material.
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