Analysis and Design of a Pulsed Power Generator for a Low-Energy Magnetic Pulse Welding System

Abstract

Magnetic pulse welding (MPW) is a joining method that uses Lorentz force generated from an electromagnetic field. This method not only has the advantage of not causing thermal deformation of the material and no by-products compared to the method of joining by melting by heat but also enables the joining of dissimilar metals rather than the joining of the same metal. Joining dissimilar metals can reduce the weight of mechanical devices and apply them to various fields. Recent research on MPW has focused on the characteristics of bonding according to the material or structure of metal rather than on pulse power research that generates the main factor of operation. However, in the operation of MPW, a Lorentz force is generated by the induced current caused by the electromotive force created in the flyer tube and the external magnetic field in the actuator. Therefore, it is necessary to analyze and optimize the pulse power to improve reliability and to miniaturize the system to expand the MPW utilization range. In this paper, we analyzed MPW operation according to a section of the pulse power output waveform. A condition for obtaining the maximum current in the flyer tube was proposed, and a plateau-shaped waveform was derived as an ideal output waveform capable of maintaining the Lorentz force. Through analysis, the proposed pulse power device is designed as a pulse-forming network (PFN) that generates a plateau output waveform. The design specification is that the circuit of PFN (type E) is designed so that the output waveform is pulse width 10 (μs) and the maximum output current is 100 (kA), and it is verified by simulation.