Construction of physical welding windows for magnetic pulse welding of 5754 aluminum with DC04 steel
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ORIGINAL RESEARCH
Construction of physical welding windows for magnetic pulse welding of 5754 aluminum with DC04 steel C. Khalil 1 & S. Marya 1 & G. Racineux 1 Received: 3 April 2020 / Revised: 19 October 2020 / Accepted: 26 October 2020 # Springer-Verlag France SAS, part of Springer Nature 2020
Abstract Magnetic pulse welding (MPW) has potential applications where fusion welding is problematic, such as in dissimilar joints or where the very part integrity, as in electronic components, is likely to be impaired by hot environments. Mostly suited in lap configuration, its successful implementation hinges on multiple process parameters such as standoff distance between two parts, the discharge energy and the shape of inductor amongst others. From fundamental point, the impact angle and velocity are governing factors and remain difficult to apprehend via experimental approach. Numerical simulation is a viable tool to apprehend the effect of process parameters on impact angle and velocity and subsequently outline a physical weldability zone. On the contrary, the process weldability zone is experimentally determined for dissimilar joints made from A5754 on to DC 04 steel by varying the discharge energy and standoff distance using a straight I shape conductor. The shear strength of the joints is used as a marker to define the process weldability zone. Results suggest that weldability is reduced by increasing the discharge energy and standoff distance and a combination of two is required to optimize the outcome. The paper proposes to discuss process and physical weldability zones determined through numerical simulation and experimental tests. Keywords Magnetic pulse welding . Spot welds . Linear coils . Shear lap test . Automotive alloys . Numerical analysis . LS-DYNA
Introduction Magnetic pulse welding (MPW) consists in projecting at very high speed, by means of a pulsed magnetic field, one of the two parts to be assembled (called projectile part), which must be electrically conductive, onto the second part (called target part) [1–3]. Being a solid state assembly process, MPW allows to weld similar or dissimilar materials very simply, avoiding the classic defects of fusion welding processes [4]. Indeed, even if there is a significant heating of the interface, it remains very localized and lasts very little time (a few tens of microseconds) which makes it possible to limit the formation of intermetallics [5]. This process, which is similar to explosion welding [6, 7] or to laser impact welding [8] or to vaporizing foil actuator
* G. Racineux [email protected] 1
Research Institute in Civil and Mechanical Engineering (GeM, UMR 6183 CNRS), Ecole Centrale de Nantes, 1 rue de la Noë, F-44321 Nantes, France
collision welding [9], has been used successfully in many configurations (tube / tube, plate / plate with weld lines [10] or by spot [11], etc.) and for many pairs of materials. Even if it is limited to relatively small projectile thicknesses (a few millimeters) the MPW does not require filler metal, does
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