Thermal Effects in Dissimilar Magnetic Pulse Welding

Magnetic pulse welding (MPW) is often categorized as a cold welding technology, whereas latest studies evidence melted and rapidly cooled regions within the joining interface. These phenomena already occur at very low impact velocities, when the heat input due to plastic deformation is comparatively...

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Main Authors: Joerg Bellmann, Joern Lueg-Althoff, Sebastian Schulze, Marlon Hahn, Soeren Gies, Eckhard Beyer, A. Erman Tekkaya
Format: Article
Language:English
Published: MDPI AG 2019-03-01
Series:Metals
Subjects:
Online Access:http://www.mdpi.com/2075-4701/9/3/348
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author Joerg Bellmann
Joern Lueg-Althoff
Sebastian Schulze
Marlon Hahn
Soeren Gies
Eckhard Beyer
A. Erman Tekkaya
author_facet Joerg Bellmann
Joern Lueg-Althoff
Sebastian Schulze
Marlon Hahn
Soeren Gies
Eckhard Beyer
A. Erman Tekkaya
author_sort Joerg Bellmann
collection DOAJ
description Magnetic pulse welding (MPW) is often categorized as a cold welding technology, whereas latest studies evidence melted and rapidly cooled regions within the joining interface. These phenomena already occur at very low impact velocities, when the heat input due to plastic deformation is comparatively low and where jetting in the kind of a distinct material flow is not initiated. As another heat source, this study investigates the cloud of particles (CoP), which is ejected as a result of the high speed impact. MPW experiments with different collision conditions are carried out in vacuum to suppress the interaction with the surrounding air for an improved process monitoring. Long time exposures and flash measurements indicate a higher temperature in the joining gap for smaller collision angles. Furthermore, the CoP becomes a finely dispersed metal vapor because of the higher degree of compression and the increased temperature. These conditions are beneficial for the surface activation of both joining partners. A numerical temperature model based on the theory of liquid state bonding is developed and considers the heating due to the CoP as well as the enthalpy of fusion and crystallization, respectively. The time offset between the heat input and the contact is identified as an important factor for a successful weld formation. Low values are beneficial to ensure high surface temperatures at the time of contact, which corresponds to the experimental results at small collision angles.
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spelling doaj.art-d808bec857b54daba03614b5d66aef2f2022-12-22T02:32:53ZengMDPI AGMetals2075-47012019-03-019334810.3390/met9030348met9030348Thermal Effects in Dissimilar Magnetic Pulse WeldingJoerg Bellmann0Joern Lueg-Althoff1Sebastian Schulze2Marlon Hahn3Soeren Gies4Eckhard Beyer5A. Erman Tekkaya6Institute of Manufacturing Science and Engineering, Technische Universitaet Dresden, George-Baehr-Str. 3c, 01062 Dresden, GermanyInstitute of Forming Technology and Lightweight Components, TU Dortmund University, Baroper Str. 303, 44227 Dortmund, GermanyBusiness Unit Joining, Fraunhofer IWS Dresden, Winterbergstr. 28, 01277 Dresden, GermanyInstitute of Forming Technology and Lightweight Components, TU Dortmund University, Baroper Str. 303, 44227 Dortmund, GermanyInstitute of Forming Technology and Lightweight Components, TU Dortmund University, Baroper Str. 303, 44227 Dortmund, GermanyInstitute of Manufacturing Science and Engineering, Technische Universitaet Dresden, George-Baehr-Str. 3c, 01062 Dresden, GermanyInstitute of Forming Technology and Lightweight Components, TU Dortmund University, Baroper Str. 303, 44227 Dortmund, GermanyMagnetic pulse welding (MPW) is often categorized as a cold welding technology, whereas latest studies evidence melted and rapidly cooled regions within the joining interface. These phenomena already occur at very low impact velocities, when the heat input due to plastic deformation is comparatively low and where jetting in the kind of a distinct material flow is not initiated. As another heat source, this study investigates the cloud of particles (CoP), which is ejected as a result of the high speed impact. MPW experiments with different collision conditions are carried out in vacuum to suppress the interaction with the surrounding air for an improved process monitoring. Long time exposures and flash measurements indicate a higher temperature in the joining gap for smaller collision angles. Furthermore, the CoP becomes a finely dispersed metal vapor because of the higher degree of compression and the increased temperature. These conditions are beneficial for the surface activation of both joining partners. A numerical temperature model based on the theory of liquid state bonding is developed and considers the heating due to the CoP as well as the enthalpy of fusion and crystallization, respectively. The time offset between the heat input and the contact is identified as an important factor for a successful weld formation. Low values are beneficial to ensure high surface temperatures at the time of contact, which corresponds to the experimental results at small collision angles.http://www.mdpi.com/2075-4701/9/3/348magnetic pulse weldingdissimilar metal weldingsolid state weldingwelding windowcloud of particlesjetsurface activation
spellingShingle Joerg Bellmann
Joern Lueg-Althoff
Sebastian Schulze
Marlon Hahn
Soeren Gies
Eckhard Beyer
A. Erman Tekkaya
Thermal Effects in Dissimilar Magnetic Pulse Welding
Metals
magnetic pulse welding
dissimilar metal welding
solid state welding
welding window
cloud of particles
jet
surface activation
title Thermal Effects in Dissimilar Magnetic Pulse Welding
title_full Thermal Effects in Dissimilar Magnetic Pulse Welding
title_fullStr Thermal Effects in Dissimilar Magnetic Pulse Welding
title_full_unstemmed Thermal Effects in Dissimilar Magnetic Pulse Welding
title_short Thermal Effects in Dissimilar Magnetic Pulse Welding
title_sort thermal effects in dissimilar magnetic pulse welding
topic magnetic pulse welding
dissimilar metal welding
solid state welding
welding window
cloud of particles
jet
surface activation
url http://www.mdpi.com/2075-4701/9/3/348
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