Abstract
Magnetic Pulse Welding (MPW) is an eco-friendly, solid-state welding method that utilizes high-velocity impacts. It operates without the necessity for fillers or flux and generates no harmful fumes. The process harnesses electromagnetic forces to weld two dissimilar job pieces by rapidly discharging current (∼100 µs) from a capacitor bank into a tool coil. This action produces a significant magnetic field (∼35 T) in the tool coil, which induces eddy currents in the job pieces, causing the outer piece to strike the inner piece at high velocities. Dissimilar metal joints such as Al-Cu, Cu-SS304, Al-SS304 and Ti-SS304 were successfully welded under these conditions using a 200 kJ MPW system. The resulting joints passed helium leak tests and exhibited a characteristic wavy morphology at the interface. Hardness measurements are conducted to investigate the mechanical properties of these joints, which provide valuable insights into the weldability and interface bond strength. Corrosion behaviour was evaluated, revealing bimetallic corrosion at the interface area. The welds were found to be flawless, instantaneous, and stronger than the base materials, confirming the potential of MPW for joining dissimilar metals with minimal corrosion rate of 0.441 mpy attained for the Ti-SS304 joint.
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