Improving and monitoring the magnetic pulse welding process between dissimilar metals
- PDF / 834,197 Bytes
- 11 Pages / 595.276 x 790.866 pts Page_size
- 10 Downloads / 215 Views
RESEARCH PAPER
Improving and monitoring the magnetic pulse welding process between dissimilar metals Joerg Bellmann 1,2 & Sebastian Schettler 1,3 & Sebastian Schulze 1 & Markus Wagner 1 & Jens Standfuss 1 & Martina Zimmermann 1,3 & Eckhard Beyer 2 & Christoph Leyens 1,3 Received: 11 July 2020 / Accepted: 3 October 2020 # The Author(s) 2020
Abstract Conventional fusion welding of dissimilar metals is often limited due to the different thermo-physical properties of the joining partners. In consequence, brittle intermetallic phases (IMC) can occur. Utilizing a pressure welding process like magnetic pulse welding (MPW) reduces the risk of IMCs significantly. Furthermore, this welding process has an outstanding short process duration in the range of a few microseconds, which makes it predestined for mass production. At the same time, this advantage challenges the process observation, inline-quality assurance hardware, and the design of the tool coils. The paper presents two strategies for reducing the energy input during MPW to increase the tool coil lifetime. The first approach, the introduction of a reactive nickel interlayer between steel and aluminum, leads to a significant welding energy reduction. Compared to aluminum samples joined by laser welding, the load-bearing capability of the resulting hybrid MPW driveshaft samples is higher in static torsion tests and similar in cyclic tests. The second approach is based on a novel process monitoring system that helps to analyze the characteristic light emission. The capability of the process monitoring system is presented on the example of a MPW-joined multimaterial part made of stainless steel, aluminum, and copper. Keywords Magnetic pulse welding . Dissimilar metal welding . Torsion test . Tightness test . Process monitoring
Nomenclature Symbol; Parameter, abbreviation C Capacity, collision point E Charging energy fdischarge Discharge frequency g Initial joining gap
Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process * Joerg Bellmann [email protected] 1
Fraunhofer IWS Dresden, Winterbergstr. 28, 01277 Dresden, Germany
2
Institute of Manufacturing Science and Engineering, Technische Universität Dresden, George-Baehr-Str. 3c, 01062 Dresden, Germany
3
Institute of Materials Science, Technische Universität Dresden, Helmholtzstr. 7, 01069 Dresden, Germany
I If Imax lweld Li lw pm Ri sf sp S t ti tf,start Umax vc vi vi,r β γ
Discharge current Intensity of the impact flash Maximum discharge current Length of welded zone Inner inductance of the pulse generator Working length Magnetic pressure Inner resistance of the pulse generator Wall thickness of the flyer tube Wall thickness of the parent tube High voltage switch Time Impact time Flash appearance time Maximum charging voltage Axial collision point velocity Impact velocity Radial impact velocity Collision angle Damping coefficient of I(t)
Weld World
1 Introduction Technical structures often consist of dissimilar metals, in order to
Data Loading...
