Feasibility studies on magnetic pulse welding of non ferrous materials employed in automotive applications

Abstract

The key focus of this research study is to investigate the feasibility of magnetic pulse joining process for joining dissimilar material tubes with dissimilar diameter. Magnetic pulse joining process exploits the electromagnetic force created between the work piece and the coils owing to the eddy current produced in the work piece for joining. This process yields a cold solid state weld at room temperature at a very short time interval of few microseconds for all acceptable dimensions. The joint demonstrates higher strength than the base metal while the process eliminates the need for filler material or any shielding gases respectively. The phenomenon governing the magnetic pulse joining process is the molecular diffusion due to intense vibration and impact among the work pieces that facilitates in achieving a cold welding process that eludes the existence of any heat affected zone. The work pieces specifically being conductive in nature is sand witched between the coils that promotes acceleration to an extent of few mm to impact the other work piece swiftly. The generated acceleration eventually results in the formation of repelling magnetic fields among the coil and the work piece consequential to the eddy current generation in the work piece. Cold solid state joints are achieved subsequent to the two metals being forced onto each other which high intensity leading to sharing of electrons among atoms and ultimately fusing the two metals. With the absence of heat, this process is a preferred choice for dissimilar material joining newline newline newline