Magnetic pulse technology mpt formingwelding is a highspeed metal processing technology which uses electromagnetic force to form or weld various materials, and is especially good for aluminum and copper alloys that have a high electrical conductivity. Electromagnetic pulse welding of fluid joints download pdf info publication number us7847223b2. Workers exposure to electromagnetic fields from welding. Review on electromagnetic welding of dissimilar materials. Although this technique has been implemented by some giant manufacturers for various joining tasks, the process still has not been well adopted by industries.
Us7847223b2 us11865,452 us86545207a us7847223b2 us 7847223 b2 us7847223 b2 us 7847223b2 us 86545207 a us86545207 a us 86545207a us 7847223 b2 us7847223 b2 us 7847223b2 authority us. The magnetic field shaper that is placed between the metal components and an electromagnetic coil is used to concentrate the magnetic field around the weld zone and then enhance the generated lorentz force acting on the metal. The objective of this work is to propose a magnetic pulse spot welding mpsw process with the aid of a field shaper for achieving the connecting of metal components. In the magnetic pulse welding process, welding is achieved by the pressure for outer workpiece that only uses the electromagnetic force which takes advantage of flemings lefthand rule.
Extended efforts have been made to imhowever, the extent and potentially prove theoretical models and to develop serious nature of emp effects were not associated computer codes for predicrealized for several years. Electromagnetic pulse forming of carbon steel sheet metal r. Electromagnetic pulse welding of magnesium to aluminium. Electromagnetic pulse technology empt for joining, welding. An emp or e lectro m agnetic p ulse is a wave of electromagnetic radiation. The aim of the legislation is to protect workers from the risks associated with electromagnetic fields, so it is mainly applicable to manual processes such as resistance welding using pedestal welders, portable spot welding guns and arc welding. Extremely high velocity and strain rate involved in. The workpiece is reshaped by high intensity pulsed magnetic fields that induce a current in the workpiece and a corresponding repulsive magnetic field, rapidly repelling portions of the workpiece. Groche1 1 institute for production engineering and forming machines, tu darmstadt, germany abstract most researches on the mechanisms of impact welding in general base their results on. This study shows the transmission efficiency of the electromagnetic energy which move from the bank to the coil. Electromagnetic pulse welding facility consists of power supply, hmi control, capacitor banks, trigger generators, spark gaps and empw actuators figure 2 shows the general outlines of the magnetic pulse welding apparatus, which consists of a capacitor bank c and a spark gap switch g with a onelayer, e shaped flat coil. Oct 30, 2019 impact welding is a procedure which establishes metallurgical bonds, even between metals that are not similar. Strategies, protections, and mitigations for the electric. For achieving the successful weldment and using this process, the design of working coil is the most important factor.
Electromagnetic pulse welding empw is a technique for welding of metals by means of plastic deformation generated by a repulsive force on account of the interaction between the magnetic field of the coil and the current induced in the workpiece. The mpw is sufficiently flexible to weld various shapes of components for different joint configurations such as half lap, overlap, cross lap and end lap section 2. Distribution of electromagnetic force of square working. Us20060208481a1 electromagnetic pulse welding of fluid. A metallurgically formed fluid circuit joint includes a hollow fitting 298, a tubular conduit 297, and a metallurgically formed tubefitting mesh 296. A high pulse current from a capacitor bank is discharged through an insulated flat coil for magnetic abstract pulse welding of sheets. Effect of the welding parameters on the structural and. Electromagnetic energy transmission in magnetic pulse. Iwsnewsletter 012016 electromagnetic pulse welding. Read online electromagnetic pulse emp protection and resilience. A hemp is a high amplitude short duration, broadband pulse of. One of the threats oe is concerned about is a highaltitude electromagnetic pulse hemp from a nuclear explosion and electromagnetic pulse emp or an early time e1 pulse which can be generated by emp weapons. Magnetic pulse welding mpw applies the electromagnetic principles postulated in the xixth century and later demonstrated.
Once it was widely thought to be an exceptional innovative welding solution, the magnetic pulse welding, dragged the related manufacturing industries and particularly automobile companies for its complex assembly solutions in early 2000s. Electromagnetic pulse welding epw is an effective way to realize the connection of two different kinds of metal. Abstractelectromagnetic pulse welding can be categorised as a fast, precise, and contactless solidstate joining process. Us7847223b2 electromagnetic pulse welding of fluid joints. A large one could knock out power or kill electronic. Electromagnetic pulse welding is an innovative solidstate welding technology that belongs to the group of pressure welding processes. Due to the ease of controlling magnetic fields, em technique is more suitable for joining axis symmetric components. Process insights by high speed imaging and numerical simulation c. Jun 27, 2018 the objective of this work is to propose a magnetic pulse spot welding mpsw process with the aid of a field shaper for achieving the connecting of metal components. Coupled electromagnetic structural simulation of magnetic.
Coupled electromagneticstructural simulation of magnetic pulse welding angshuman kapil and abhay sharma abstract the present study deals with the coupled magneticstructural analysis of magnetic pulse welding mpw process applied on a tubular workpiece. Idaho national laboratory inl was chosen to conduct the emp study for doeoe. In the present study, a thermomechanically coupled dynamic model has been developed to quantitatively resolve the high. The aim of this study was to identify and analyze the fatigue fracture characteristics of dissimilar al 6061 to cu uns c1 lap joints made with ultrafast electromagnetic pulse welding empw via fractography, stress analysis and finite element simulation. Magnetic pulse welding on the cutting edge of industrial. This technique uses electromagnetic force to mainly join conductive materials. Highaltitude nuclear detonations and electromagnetic bombs can generate emp that. Magnetic pulse welding diagram equipment application. By utilizing this coil, joints of up to 120 mm can be created within a single pulse process.
For empt processing electromagnetic coils are used, to which a short but very highpower electric current is applied from a pulse generator. The study investigates the various criteria required for a successful weld between the. Pdf electromagnetic energy transmission in magnetic pulse. Process equipment joint examples for electromagnetic pulse welding of flat sheets fraunhofer iws has developed a special flat coil. An emp does not directly hurt people, but an emp interacts with power lines, metal, conductive materials and electronics and causes power spikes. Pdf magnetic pulse welding technology ahmad jassim. Magnetic pulse welding and forming are unique high speed. Electromagnetic energy transmission in magnetic pulse welding. Dec 07, 2010 the present invention is related to u. Electromagnetic pulse technology empt provides noncontact process for joining, welding, forming and cutting metals with great potential to join similar and dissimilar materials besides the conventional welding techniques often used in the industry. Electromagnetic welding emw is a highspeed joining technique that is used to join similar or dissimilar metals, as well as metals to nonmetals. The magnetic field shaper that is placed between the metal components and an electromagnetic coil is used to concentrate the magnetic field around the weld zone and then enhance the generated lorentz force acting on the. The tubefitting mesh 296 includes a fitting portion of the hollow fitting 298 and a tube portion of the tubular conduit 297 that is electromagnetically formed with the fitting portion.
The type of welding process which uses magnetic forces to weld two workpieces together is called magnetic pulse welding. Pdf electromagnetic energy transmission in magnetic. Electromagnetic pulse welding of fluid joints the boeing. Magnetic pulse welding mpw method for dissimilar sheet metal joints.
An emp or hemp high altitude emp usually occurs in a broadband nature. The electrical energy stored in the magnetic pulse power source is discharged. The process can be used to join tubular 1 and sheet metals 2, placed in the overlap. Magnetic pulse welding mpw is another noncontact solidstate welding process, completed in microsecond time using the lorentz force formed in magnetic fields. Impact welding is a procedure which establishes metallurgical bonds, even between metals that are not similar. Dec 23, 2016 electromagnetic welding emw is a highspeed joining technique that is used to join similar or dissimilar metals, as well as metals to nonmetals. A hemp is a high amplitude short duration, broadband pulse of electromagnetic energy.
The past research work in this field shows that the auto ignition of aluminum powder with a particle size of under 10 m can already happen at. Us20080036204a1 electromagnetic pulse welding of fluid. Magnetic pulse technology mpt forming welding is a highspeed metal processing technology which uses electromagnetic force to form or weld various materials, and is especially good for aluminum and copper alloys that have a high electrical conductivity. Electromagnetic pulse welding can be used for tubular and sheet applications, placed in the overlap configuration. Electromagnetic pulse welding of two aluminum sheets with left and without right inert gas atmosphere. Fracture characteristics and analysis in dissimilar cual. In recent years the process has been developed to meet highly demanding market needs involving dissimilar material joining, specially involving difficulttoweld materials. Us7847223b2 electromagnetic pulse welding of fluid. Its mechanism is similar to explosion welding technique. All books are in clear copy here, and all files are secure so dont worry about it.
Emp threats are one of the largest electromagnetic threats of this time. Numerical investigation of electromagnetic pulse welded. Electromagnetic coupling exists between the coil and the al sheet near the coil. With special coil design, it can also be used to join mg to al sheets. Method of magnetic pulse welding an end fitting to a driveshaft tube of.
The application of this coil allows transferring the advantages of the method on larger geometries, while creating more. Magnetic pulse welding mpw is another noncontact solidstate welding process, completed in microsecond time using the lorentz force formed in magnetic fields as driving force 8. Magnetic pulse welding process, one of high speed welding processes, uses electromagnetic force from discharged current through a working coil which develops a repulsive force between the induced currents flowing parallel and in the opposite direction in the pipe to be welded. The quality of an electromagnetic pulse weld is strongly affected by a variety of interacting physical phenomena including large plastic deformation, materials mixing, localised heating and rapid cooling, and possible localised melting and interfacial cracks and void. Electromagnetic pulse emp protection and resilience. The electromagnetic pulse technology empt provides noncontact processes for joining, welding, forming and cutting of metals. Us11865,452 electromagnetic pulse welding of fluid joints us7847223b2 en. Electromagnetic pulse welding can be categorised as a fast, precise, and contactless solidstate joining process. Iwsnewsletter 012016 electromagnetic pulse welding an.
Jun 14, 2015 magnetic pulse forming and welding by mps5. Magnetic pulse welding is based on a very short electromagnetic pulse pdf available september 2011. The sheets alcu with a gap are overlapped and fixed on the coil. The auto ignition temperature of aluminum strongly depends on the particle size. Electromagnetic energy transmission in magnetic pulse welding of alcu sheets using 1, 3, 4 and 6 turn flat coils tomokatsu aizawa tokyo metropolitan college of technology 11040, higashiohi, shinagawaku, tokyo 1400011, japan email. Download electromagnetic pulse emp protection and resilience. Magnetic pulse welding is a solid state cold welding. The workpiece is reshaped by high intensity pulsed magnetic fields that induce a current in the workpiece and a corresponding repulsive magnetic field, rapidly repelling. Interfacial microstructures and temperatures in aluminium. When applied to aluminium and copper, electromagnetic pulse welding opens the possibility of entirely suppressing, or at least minimising, the intermetallic phases of cracking susceptible microstructures. Mps electromagnetic magnetic pulse forming and welding.
Industrialisation of electromagnetic pulse technology. In very large events an emp can cause electronic systems failures. Using aluminum alloys for automotive components could reduce vehicle body structure weight and using these alloys is receiving much attention. Unlike conventional joining processes, the weld interface does not melt, thus keeping the material properties intact. Pdf magnetic pulse welding mpw method for dissimilar. Electromagnetic pulse welding has been produced as one technique for impact welding. Introduction electromagnetic pulse welding is an innovative solidstate welding technology that belongs to the group of pressure welding processes. Electromagnetic pulse forming of carbon steel sheet metal. Electromagnetic forming em forming or magneforming is a type of high velocity, cold forming process for electrically conductive metals, most commonly copper and aluminium. It was observed that empw generated an annular or ringshaped bonding area, with weld zones and a central nonweld zone when viewed. Electromagnetic em welding is based on application of amperes law. Emp can also be produced from nonnuclear sources, such as electromagnetic bombs, or ebombs.
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