Magnetic pulse welding of copper to steel tubes–Experimental investigation and process modelling

Shotri, Rishabh; Faes, Koen; De, A.

doi:10.1016/j.jmapro.2020.07.061

Cited by 23 publications

(20 citation statements)

References 24 publications

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“…A direct analytical solution of the governing equation (Equation ( 1)) along with the necessary boundary conditions (Equations ( 2) and ( 3)) is very difficult, if not impossible [32]. Efforts to numerically calculate the transient EM field by solving the governing equation along with the necessary boundary conditions using finite element methods are reported for MPW of tubes [5,33] and sheets [3,34]. These efforts are a testimony of several inherent computational challenges, such as the requirement of very fine element sizes to discretize the solution domain as well as the use of very small time-steps to model the steep gradient of the EM field and its evolution [3,33].…”

Section: Process Mechanics and Theoretical Backgroundmentioning

confidence: 99%

“…Efforts to numerically calculate the transient EM field by solving the governing equation along with the necessary boundary conditions using finite element methods are reported for MPW of tubes [5,33] and sheets [3,34]. These efforts are a testimony of several inherent computational challenges, such as the requirement of very fine element sizes to discretize the solution domain as well as the use of very small time-steps to model the steep gradient of the EM field and its evolution [3,33]. To keep the modelling calculations manageable, many simplifications are considered.…”

Section: Process Mechanics and Theoretical Backgroundmentioning

confidence: 99%

“…x i and b i are the final and initial acceleration and F i is the applied force at the ith point of the flyer with mass m. The numerical solution of Equation ( 5) for the calculation of the flyer impact velocity and the deformation of the flyer-target assembly is also challenging as it requires a fairly accurate estimation of the dynamic mechanical behavior of the materials at a high strain rate [35]. As the flyer-target assembly undergoes a progressive deformation along the overlapped length, a fine mesh of the solution domain with a large number of discrete elements is a requisite [33,37,38]. The transient change of the EM field as the flyer moves away from the coil further requires a coupled field analysis, which is often neglected [39].…”

Section: Process Mechanics and Theoretical Backgroundmentioning

confidence: 99%

“…The transient change of the EM field as the flyer moves away from the coil further requires a coupled field analysis, which is often neglected [39]. Recent efforts involved an independent calculation of the EM field and pressure at considering the deformed flyer-target assembly at discrete time-steps, which required a significant volume of computational time and resources [33].…”

Section: Process Mechanics and Theoretical Backgroundmentioning

confidence: 99%

“…The joint length is referred to the intimate contact along the flyer-target interface as a result of the EM pressure of the flyer, its progressive impact on the target and the consequent visco-plastic deformation of the flyer-target assembly [3,5]. The joint length is often observed using microscopy and measured by means of peel tests [2,7,33]. The finite element method based computational models for MPW have construed the joint length by examining the segment of the flyer that is in close contact with the target along the flyertarget interface [2,5,7].…”

Section: Formulation For the Joint Lengthmentioning

confidence: 99%

See 4 more Smart Citations

Analytical Estimation of Electromagnetic Pressure, Flyer Impact Velocity, and Welded Joint Length in Magnetic Pulse Welding

Shotri

Faes

Racineux

et al. 2022

Metals

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Magnetic pulse welding involves the joining of two metallic parts in a solid state by the use of a short and intense electromagnetic impulses and the resulting impact between the parts. The coalesced interface undergoes visco-plastic deformation at a high strain rate and exhibits a wavy shape at a microscopic scale. A practical estimation of the electromagnetic pressure, impact velocity and welded joint length as a function of the process conditions and the electromagnetic coil geometry is required but currently not available. Three novel analytical relations for the estimation of the electromagnetic pressure, impact velocity, and welded joint length for magnetic pulse welding of tubes and sheets, are presented. These relations were developed systematically, following a dimensional analysis, and validated for a wide range of conditions from independent literature. The comparison of the analytically computed results and the corresponding values reported in the literature has illustrated that the proposed analytical relations can be used for the estimation of the electromagnetic pressure and impact velocity for the magnetic pulse welding of tubes and sheets with a good level of confidence. The analytically calculated results for the welded joint length show a little discrepancy with the corresponding experimentally measured values. Further investigations and more experimentally measured results are required to arrive at a more comprehensive analytical relation for the prediction of welded joint length.

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