Distribution of Electromagnetic Field and Pressure of Single-Turn Circular Coil for Magnetic Pulse Welding Using FEM

  • Mohammed Rajik KhanEmail author
  • Alok Raj
  • Md. Mosarraf Hossain
  • Satendra Kumar
  • Archana Sharma
Conference paper
Part of the Lecture Notes on Multidisciplinary Industrial Engineering book series (LNMUINEN)


Magnetic pulse welding (MPW), which is uniquely advantageous in welding electrically conductive similar and dissimilar pipe fittings, is a contactless welding technology based on high-speed magnetic impulse shaping and solid-phase diffusion welding. This has proven to be an effective solution to specific manufacturing problems, especially for leak-proof dissimilar pipe joints required to sustain high pressure, which is very difficult to achieve by conventional techniques. For achieving the successful weldament, it is essential to understand the effect of various process parameters to generate proper weldability window. In the present work, the distribution of electromagnetic force and magnetic field of single-turn circular coil for MPW has been investigated using FE simulation. A three-dimensional (3D) electromagnetic FE model has been developed using commercially available ANSYS-EMAG application software. A single-turn inductor coil of Cu material is chosen for the analysis. Compression joining of tubular metallic assembly with flyer tube as Al6061 and target tube as SS304 is simulated in ANSYS Maxwell 3D to study the influence of varying process parameters like air gap between the tubes, tube thickness, and gap between the flyer tube and the coil with respect to the input voltage. FE simulation results for weld formation are verified with the analytical results and the data available in the literature. The study reveals that for effective welding, estimation of electromagnetic field and electromagnetic force has a significant role which is governed by the process parameters of applied voltage and air gap. The presented information can assist to understand process physics, coil reliability, and prediction of mechanical behavior of the workpiece.


Magnetic pulse welding FE model MPW coil Magnetic field and pressure distribution 



The authors gratefully acknowledge the financial support provided to this study by the Advanced Technology Committee of BRNS Mumbai, India under project reference No. 2015013407RP00729-BRNS.


  1. 1.
    Findik, F.: Recent developments in explosive welding. Mat. Design 32(3), 1081–1093 (2011)MathSciNetCrossRefGoogle Scholar
  2. 2.
    Fukumoto, S., Tsubakino, H., Okita, K., Aritoshi, M., Tomita, T.: Friction welding process of 5052 aluminium alloy to 304 stainless steel. Mat. Sci. Technol. 15(9), 1080–1086 (1999)CrossRefGoogle Scholar
  3. 3.
    Park, Y.B.: Design of joints for the automotive spaceframe with electromagnetic forming and adhesive bonding. In: The Degree Doctor of Philosophy in the Graduate School of the Seoul National University, pp. 1–8 (2004)Google Scholar
  4. 4.
    Guo, X., Tao, J., Wang, W., Li, H., Wang, C.: Effects of the inner mould material on the aluminium–316L stainless steel explosive clad pipe. Mater. Des. 49, 116–122 (2013)CrossRefGoogle Scholar
  5. 5.
    Tabatabaee, M., Mahmoudi J.: Finite element simulation of explosive welding (2008)Google Scholar
  6. 6.
    Mousavi, A.A.A., Joodaki, G.: Explosive welding simulation of multilayer tubes. In: International Conference on Comput. Plast., Barcelona (2005)Google Scholar
  7. 7.
    Bahmani, A., Niayesh, K., Karimi, A.: 3D simulation of magnetic field distribution in electromagnetic forming systems with field-shaper. J. Mat. Process. Technol. 209(5), 2295–2301 (2009)CrossRefGoogle Scholar
  8. 8.
    Deng, J., Li, C., Zhao, Z., Tu, F., Haiping, Y.U.: Numerical simulation of magnetic flux and force in electromagnetic forming with attractive force. J. Mat. Process. Technol. 184(1), 190–194 (2007)CrossRefGoogle Scholar
  9. 9.
    Aizawa, T., Kashani, M., Okagawa, K.: Application of magnetic pulse welding for aluminum alloys and SPCC steel sheet joints. Weld. J. 5(86), 119–124 (2007)Google Scholar
  10. 10.
    Kore, S.D., Date, P.P., Kulkarni, S.V., Kumar, S., Rani, D., Kulkarni, M.R., Desai, S.V., Rajawat, R.K., Nagesh, K.V., Chakravarty, D.P.: Application of electromagnetic impact technique for welding copper-to-stainless steel sheets. Int. J. Adv. Manuf. Technol. 54(9), 949–955 (2011)CrossRefGoogle Scholar
  11. 11.
    Kore, S.D., Date, P.P., Kulkarni, S.V., Kumar, S., Rani, D., Kulkarni, M.R., Desai, S.V., Rajawat, R.K., Nagesh, K.V., Chakravarty, D.P.: Electromagnetic impact welding of Al-to-Al–Li sheets. J. Manuf. Sci. Eng. 54(9), 949–955 (2009)Google Scholar
  12. 12.
    Kore, S.D., Date, P.P., Kulkarni, S.V., Kumar, S., Rani, D., Kulkarni, M.R., Desai, S.V., Rajawat, R.K., Nagesh, K.V., Chakravarty, D.P.: Electromagnetic impact welding of copper-to-copper sheets. Int. J. Mat. Form. 2(3), 117–121 (2010)CrossRefGoogle Scholar
  13. 13.
    Raoelison, R.N., Buiron, N., Rachik, M., Haye, D., Franz, G., Habak, M.: Study of the elaboration of a practical weldability window in magnetic pulse welding. J. Mat. Process. Technol. 213(8), 1348–1354 (2013)CrossRefGoogle Scholar
  14. 14.
    Shim, J.Y., Kang, B.Y.: Distribution of electromagnetic force of square working coil for high-speed magnetic pulse welding using FEM. Mat. Sci. Appl. 4, 856–862 (2013)Google Scholar
  15. 15.
    Xu, Z., Cui, J., Yu, H., Li, C.: Research on the impact velocity of magnetic impulse welding of pipe fitting. Mat. Design 49, 736–745 (2013)CrossRefGoogle Scholar
  16. 16.
    Cui, J., Sun, G., Xu, J., Xu, Z., Huang, X., Li, G.: A study on the critical wall thickness of the inner tube for magnetic pulse welding of tubular Al–Fe parts. J. Mat. Process. Technol. 227, 138–146 (2016)CrossRefGoogle Scholar
  17. 17.
    Kapil, A., Sharma, A.: Coupled electromagnetic–structural simulation of magnetic pulse welding. In: Advances in Material Forming and Joining, Springer India, pp. 255–272 (2015)Google Scholar
  18. 18.
    Nassiri, A., Campbell, C., Chini, G., Kinsey, B.: Analytical model and experimental validation of single turn, axi-symmetric coil for electromagnetic forming and welding. Proced. Manuf. 1, 814–827 (2015)CrossRefGoogle Scholar
  19. 19.
    Shanthala, K., Sreenivasa, T.N.: Review on electromagnetic welding of dissimilar materials. Front. Mech. Eng. 11(4), 363–373 (2016)CrossRefGoogle Scholar
  20. 20.
    Shribman, V.: Magnetic pulse welding of automotive HVAC parts. Rapport Tech. Pulsar Ltd 8, 41–42 (2007)Google Scholar
  21. 21.
    Broeckhove, J., Willemsens, L.: Experimental research on magnetic pulse welding of dissimilar metals. Dissertation for the Master’s Degree, Ghent University (2010)Google Scholar
  22. 22.
    Knight, D.W.: Solenoid inductance calculation, January (2013).

Copyright information

© Springer Nature Singapore Pte Ltd. 2019

Authors and Affiliations

  • Mohammed Rajik Khan
    • 1
    Email author
  • Alok Raj
    • 1
  • Md. Mosarraf Hossain
    • 1
  • Satendra Kumar
    • 2
  • Archana Sharma
    • 2
  1. 1.Department of Industrial DesignNational Institute of Technology RourkelaRourkelaIndia
  2. 2.Accelerator and Pulse Power DivisionBhabha Atomic Research CenterMumbaiIndia

Personalised recommendations