The Study of Aluminum Pipes and Rods of Various Geometries Jointing by Electromagnetic Pulse Welding

Metallurgy and Material Science


Аuthors

Ahmed Soliman M. E.*, Kurlaev N. V.**

Novosibirsk State Technical University, 20, prospect Karla Marksa, Novosibirsk, 630073, Russia

*e-mail: axmed_soliman@corp.nstu.ru
**e-mail: kurlaev@corp.nstu.ru

Abstract

Magnetic pulse welding (MPW) is a solid-state welding process that can be used to weld similar and dissimilar metals using a high-speed impact without creating a weld pool. The MPW process is a type of explosive welding technique. Likewise, it involves accelerating the workpiece using magnetic pressure created by a high pulse current in a coil. The high-speed impact between the parts to be joined can cause welding if the appropriate conditions are met. The magnetic field created by eddy currents is opposite to the magnetic field in the coil. The repulsive forces between the two magnetic fields cause the outer workpiece to accelerate in the direction of the inner workpiece. Depending on the parameter settings, geometric configuration and dimensions, a crimp connection is obtained. The most important application of electromagnetic forming (EMF) is the joining by crimping elements of tubular parts of aircraft using a strong pulsed magnetic field to accelerate the parts relative to each other, thus forming a solid-state impact joint, in which the conductive metal is accelerated and impacts the target metal with high energy, thus forming a metallurgical bond. A single-turn coil and a field former (FF) are used. The modeling of such high-speed forming process must take into account numerous mechanical, electrical and electromagnetic characteristics of the material and sometimes even temperature dependence, which usually leads to nonlinear calculations. One of the most important interactions of physical fields is the mutual dependence between the acting loads and deformation. Therefore, a joint modeling of the structure and the magnetic field is required. In this study, exemplary industrial joints produced by EMF are considered. Three-dimensional joint modeling of the connection process is carried out using the LS-DYNA EM module and the crimping of mechanical connections of D16AM tubes with an internal diameter of 21 mm, a thickness of 2.5 mm with a D16AM rod of various geometries is demonstrated. The impact speed and time are estimated using analytical equations, and the morphology of the weld surface is also studied, and it is found that it has a wavy nature.

Keywords:

magnetic-pulse welding, high-speed impact welding, flyer and target tubes, field former, impact velocity, Lorentz force, 3D modeling, skin layer, finite element method, SPH numerical model, weldability window, tubular parts of aircraft

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