Abstract
Bimetal tubes have useful applications in various industries where service conditions demand more different requirements in the tube core than its outside surface. The recent use of electromagnetic forces to deform or join metallic workpieces at high speeds has undergone rapid growth for materials processing. However, to date, no sufficient systematic understanding of the underlying principles of a subsequent high-speed electromagnetic tube bulging process to manufacture bimetal tubes has been gained. In this work, magnetic pulse cladding of Al/Fe clad bimetal tubes was analyzed by finite element modeling (FEM) using ANSYS software. The validity of FEM analyses was first confirmed by experiments in terms of the deformed shape. Second, the effect of cladding parameters (such as axial feeding being the dominant factor in the multi-step process) on the bulging and thinning behavior of the Al clad tube was presented in detail. Both the numerical simulation and experimental results show that no more than 70% of the bulging-coil length is an appropriate amount for the feeding length to prevent defects from being introduced by non-uniform deformation in the transition zone of the Al clad tube. The distributions of the magnetic flux line, magnetic force, and plastic strain in different cladding steps were then analyzed. It was concluded that during the multi-step cladding process, there was an uneven distribution of the magnetic field force along the transition zone. Consequently, inharmonious plastic deformation behavior occurs, which results in a limited acceleration of the transition zone to a certain impact velocity.
Similar content being viewed by others
References
Lapovok R, Ng HP, Tomus D et al (2012) Bimetallic copper-aluminium tube by severe plastic deformation. Scr Mater 66(12):1081–1084
Li WY, Wen Q, Yang XW et al (2017) Interface microstructure evolution and mechanical properties of Al/Cu bimetallic tubes fabricated by a novel friction-based welding technology. Mater Des 134:383–393
Zhan ZL, He YD, Wang D et al (2006) Cladding inner surface of steel tubes with Al foils by ball attrition and heat treatment. Surf Coat Technol 201(6):2684–2689
Balasubramanian V, Rathinasabapathi M, Raghukandan K (1997) Modeling of process parameters in explosive cladding of mild steel and aluminum. J Mater Process Technol 63(1–3):83–88
Henryk D, Maciej P (1983) On the theory of the process of hot rolling of bimetal plate and sheet. J Mech Work Technol 8(4):309–325
Wang XS, Li PN, Wang RZ (2005) Study on hydro-forming technology of manufacturing bi-metallic CRA-lined pipe. Int J Mach Tools Manuf 45(4–5):373–378
Mohebbi MS, Akbarzadeh A (2010) A novel spin-bonding process for manufacturing multilayered clad tubes. J Mater Process Technol 210(3):510–517
Zhang ZP, Xu WC, Gu TS et al (2018) Fabrication of steel/aluminum clad tube by spin bonding and annealing treatment. Int J Adv Manuf Technol 94(9–12):3605–3617
Krishna BV, Venugopal P, Rao KP (2005) Co-extrusion of dissimilar sintered P/M performs: an explored route to produce bi-metallic tubes. Mater Sci Eng A 407(1–2):77–83
Haghighat H, Mahdavi MM (2013) Analysis and FEM simulation of extrusion process of bimetal tubes through rotating conical dies. Trans Nonferrous Met Soc China 23(11):3392–3399
Fan ZS, Yu HP, Meng FC et al (2016) Experimental investigation on fabrication of Al/Fe bi-metal tubes by the magnetic pulse cladding process. Int J Adv Manuf Technol 83(5–8):1409–1418
Fan ZS, Yu HP, Li CF (2016) Plastic deformation behavior of bi-metal tubes during magnetic pulse cladding: FE analysis and experiments. J Mater Process Technol 229:230–243
Yu HP, Li CF (2007) Effects of coil length on tube compression in electromagnetic forming. Trans Nonferrous Met Soc China 17(6):1270–1275
Mamalis AG, Manolakos DE, Kladas AG et al (2006) Electromagnetic forming tools and processing conditions: numerical simulation. Mater Manuf Processes 21(4):411–423
Cui XH, Mo JH, Li JJ et al (2014) Electromagnetic incremental forming (EMIF): a novel aluminum alloy sheet and tube forming technology. J Mater Process Technol 214(2):409–427
Cui XH, Mo JH, Li JJ et al (2017) Tube bulging process using multidirectional magnetic pressure. Int J Adv Manuf Technol 90(5–8):2075–2082
Siddiqui MA, Correia JPM, Ahzi S et al (2009) Electromagnetic forming process: estimation of magnetic pressure in tube expansion and numerical simulation. Int J Mater Form 2(1):649–652
Acknowledgements
This work was supported by the National Natural Science Foundation of China (Grant Nos. 51705081, 51774097). The authors would like to thank the financial support from the Natural Science Foundation of Fujian Province (Grant No. 2018J05079); the Youth Teacher Educational Research fund of Fujian Provincial education office (Grant No. JAT170092); the Key Project of the Youth Natural Science Fund of Fujian Provincial University (Grant No. JZ160417); Fuzhou University Fund (Grant No. XRC-1676); Fuzhou University Testing Fund of Precious Apparatus (Grant No. 2017T020).
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Fan, ZS., Huang, ST. & Deng, JH. Cladding of aluminum alloy 6061-T6 to mild steel by an electromagnetic tube bulging process: finite element modeling. Adv. Manuf. 7, 73–83 (2019). https://doi.org/10.1007/s40436-018-00247-w
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s40436-018-00247-w