Experimental Study and Numerical Simulation on Magnetic Pulse Welding for Pre-Flanged AA6061-T6 and Cu101 Sheets


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Magnetic Pulse Welding (MPW) is a solid-state impact welding process, similar to Explosive Welding (EXW), but it utilizes electromagnetic force as the acceleration mechanism. Therefore, the available energy is much lower than EXW and it makes the process safer and more reproducible. However, the available energy must be better focused and controlled. In MPW process, a flyer sheet is driven and collides with a target sheet. True metallic bonding is achieved at the mating interface if contact takes place above a critical impact velocity at an appropriate impact angle. The impact velocity and angle are determined by the primary and induced electromagnetic fields. Both of them are strongly related to the geometry of the electromagnetic actuator and the discharge characteristics. An MPW launch system that will robustly provide bonding can either be developed empirically or through simulation. Here we attempt to provide the basis for a simulation-based approach to system design. The oblique MPW impact of AA6061-T6 and Cu101 sheets were analyzed using the newly available Electromagnetism (EM) module in LS-DYNA (R). This module allows for coupled mechanical, thermal, electromagnetic simulations. The simulation can predict the impact velocities and the temperature distribution along the mating interface. Simulations indicated rapid thermal cycling on the mating interface. In our study, the simulation results were validated with experimental measurement by Photon Doppler Velocimetry (PDV).
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