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Parameter identification for magnetic pulse welding applications

: Bellmann, Jörg; Lueg-Althoff, Jörn; Schulze, Sebastian; Gies, Soeren; Beyer, Eckhard; Tekkaya, A. Erman


Bay, Niels (Ed.); Nielsen, Chris V. (Ed.):
Tribology in Manufacturing Processes and Joining by Plastic Deformation II
Zürich: Trans Tech Publications, 2018 (Key engineering materials 767)
ISBN: 978-3-0357-1299-5
ISBN: 978-3-0357-3299-3
International Conference on Tribology in Manufacturing Processes & Joining by Plastic Deformation (ICTMP) <8, 2018, Elsinore>
Deutsche Forschungsgemeinschaft DFG
Fügen durch plastische Deformation; BE 1875/30-3
Gezielte Einstellung der Nahtausbildung beim Fügen durch Magnetpulsschweißen
Conference Paper
Fraunhofer IWS ()
Collision conditions; Collision Front Velocity; Impact velocity; Magnetic pulse welding; Process Development; Solid State Bonding

Magnetic pulse welding (MPW) is a promising technology to join dissimilar metals and to produce multi-material structures, e.g. to fulfill lightweight requirements. During this impact welding process, proper collision conditions between both joining partners are essential for a sound weld formation. Controlling these conditions is difficult due to a huge number of influencing and interacting factors. Many of them are related to the pulse welding setup and the material properties of the moving part, the so-called flyer. In this paper, a new measurement system is applied that takes advantage of the high velocity impact flash. The flash is a side effect of the MPW process and its intensity depends on the impact velocity of the flyer. Thus, the intensity level can be used as a welding criterion. A procedure is described that enables the user to realize a fast parameter development with only a few experiments. The minimum energy level and the optimum distance between the parts to be joined can be identified. This is of importance since a low energy input decreases the thermal and mechanical shock loading on the tool coil and thus increases its lifetime. In a second step, the axial position of the flyer in the tool coil is adjusted to ensure a proper collision angle and a circumferential weld seam.