Abstract
Magnetic pulse welding process, one of high speed welding processes, uses electromagnetic force from discharged current through a working coil which develops a repulsive force between the induced currents flowing parallel and in the opposite direction in the pipe to be welded. For achieving the successful weldment and using this process, the design of working coil is the most important factor, because working coil has to generate a high-intensity magnetic field on the surface of the workpiece during the process. Therefore, the objective of this study is to analyze the distribution of electromagnetic force of square working coil for magnetic pulse welding. For this, FE-model has been developed to analyze the distribution of electromagnetic force; after that, distribution of electromagnetic force, results of numerical analysis and experimental results for verifying the developed FE-model were compared. A 3-dimensional electromagnetic FE-model has been developed using a general commercial computer program, ANSYS/EMAG code. The shape and material of square working coil were decided through literature surveys. For the experiment, an MPW equipment W-MPW manufactured by WELDMATE Co., Ltd. was employed; also the materials were the Al 1070, SM45C for Al and Steel square pipe and rod respectively. After the experiment, leakage test was used to verify the weldability. Also weld joints were observed on longitudinal cross-section by microscope. The electromagnetic force generated was the greatest one at the center adjacent to square working coil, decreasing as moving into the edge. As the result of Al/Steel welding experiment, weldment of square Al pipe was not completed at the corner of weldment. These results are similar to the output data from developed electromagnetic FE-model where electromagnetic force decreases as moving into the corners of square working coil.
Highlights
The car industry is currently working to accommodate the conflicting requirements of both environmental legislation and customer demands for high performance and safety by developing a light-weight vehicle [1]
The objective of this research is to develop FEmodel for square working coil in magnetic pulse welding which is a basic research for manufacturing the automotive space frame
The maximum electromagnetic force generated in coil is about 951 N and in the edge about 503 N was measured
Summary
The car industry is currently working to accommodate the conflicting requirements of both environmental legislation and customer demands for high performance and safety by developing a light-weight vehicle [1]. The light weight materials such as aluminum and magnesium have been applied in automation. Development of aluminum space frame for automotive body structure has been carried out in recent years [2]. When only light materials are used in automotive body structure, they cannot satisfy the required intensity and strong property, and it is imperative to weld light weight materials with existing used ones. Welding as existing fusion welding generally causes defects, such as solidification, cracking, porosity and oxidation, and transformation and corrosion. For this reason, more attention has been paid to magnetic pulse welding process as a kind of solid-state welding these days
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