Investigation of electromagnetic welding

Abstract

We propose several methodologies to study and optimize the electromagnetic process for Electromagnetic Forming (EMF) and Welding (EMW), thereby lowering the necessary process energy up to a factor of three and lengthening the life-time of EMW compression coils. We present a new theoretical approach to calculate a so-called critical kinetic energy to achieve a proper EMW joint, which is related to the volume of the accelerated mass and the Vicker's Hardness of the material. Using this novel approach, welding windows for several materials are presented. Studying the circuit theory, the current discharge pulse can be optimized to the needs of the EMW process, when opting for a critically damped RLC circuit. We present MultiSIM and MATLAB models that prove the proposed optimization and reflect the experimental EMW setup and parameters. Using the models, unknown parameters, such as machine inductance and resistance can be extrapolated for EMF and EMW machinery. Furthermore, the MATLAB model can calculate the optimal gap between the outer and inner workpiece for the outer workpiece to reach the maximum velocity at impact. Good correlation was found with regards to the High-Speed Videography used to study the EMF process in further detail measuring velocities between 50 m/s and 100 m/s. Studying the mechanical properties of the outer workpiece we propose an EMF-EMW setup that would decrease the strength of the outer workpiece by introducing a controlled amount of wrinkles through an EMF step with a mandrel inside the outer workpiece, followed by a lower critical energy EMW step.

(cont.) Through a failure study, accompanied by a metallurgical analysis, of an Aluminum Bronze Bitter coil we present a materials selection of other possible coil materials, as well as a new method called Electromagnetic Fatigue (EMFA) Analysis to study the crack initiation and propagation in electromagnetic high-current applications. Finally, through two sets of EMW experiments tubular lap joints that were stronger than the base material could be produced and the EMW process parameters of increased cleanliness, gap, wall thickness and a lower taper angle, for the case of our setup, showed to increase the final joint strength.