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Advances in Manufacturing ›› 2016, Vol. 4 ›› Issue (4): 322-339.doi: 10.1007/s40436-016-0162-5

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Measurement and analysis technologies for magnetic pulse welding: established methods and new strategies

J. Bellmann1,2, J. Lueg-Althoff3, S. Schulze2, S. Gies3, E. Beyer1,2, A. E. Tekkaya3   

  1. 1 Institute of Manufacturing Science and Engineering, TU Dresden, 01062 Dresden, Germany;
    2 Fraunhofer Institute for Material and Beam Technology, Winterbergstrasse 28, 01277 Dresden, Germany;
    3 Institute of Forming Technology and Lightweight Construction, TU Dortmund, Baroper Strasse 303, 44227 Dortmund, Germany
  • Received:2016-06-06 Revised:2016-11-01 Online:2016-12-25 Published:2016-12-25
  • Supported by:

    This work is based on the results of Subproject A1 of the Priority Program 1640 ("joining by plastic deformation");the authors would like to thank the Deutsche Forschungs gemeinschaft (DFG) for its financial support. Furthermore, the authors would like to thank "Bmax" (Toulouse, France) for preparing the samples for the torsion tests and "Telegaertner Geraetebau GmbH" (Hoeckendorf, Germany) for providing the fiberoptic components. Joerg Bellmann was supported by Deutsche Forschungsgemeinschaft through Grant No. BE 1875/30-2. Joern Lueg-Althoff was supported by Deutsche Forschungsgemeinschaft through Grant No. TE 508/39-2.

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Abstract:

Magnetic pulse welding (MPW) is a fast and clean joining technique that offers the possibility to weld dissimilar metals, e.g., aluminum and steel. The high-speed collision of the joining partners is used to generate strong atomic bonded areas. Critical brittle intermetallic phases can be avoided due to the absence of external heat. These features attract the notice of industries performing large scale productions of dissimilar metal joints, like automotive and plant engineering. The most important issue is to guarantee a proper weld quality. Numerical simulations are often used to predict the welding result a priori. Nevertheless, experiments and the measurement of process parameters are needed for the validation of these data. Sensors nearby the joining zone are exposed to high pressures and intense magnetic fields which hinder the evaluation of the electrical output signals. In this paper, existing analysis tools for process development and quality assurance in MPW are reviewed. New methods for the process monitoring and weld characterization during and after MPW are introduced, which help to overcome the mentioned drawbacks of established technologies. These methods are based on optical and mechanical measuring technologies taking advantage of the hypervelocity impact flash, the impact pressure and the deformation necessary for the weld formation.

Key words: Magnetic pulse welding(MPW), Process monitoring, Collision conditions, Dissimilar metal joining, Materials testing

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