Abstract
Magnetic pulse welding (MPW) is a high-speed joining process that uses pulse electromagnetic force to achieve welding. It is a clean welding process and it can be applied to dissimilar metals welding, which has a wide range of application prospects. However, this technology is currently mainly used for welding small-diameter thin-walled tubes. This is because the energy and electromagnetic force required for welding increase significantly as the tube size increases, which consequently places strict requirements on welding tools, including pulsed power and coil. To solve this issue, this work developed a two-dimensional (2D) axial-symmetry finite element model to optimize the tube welding process and designed a high-performance magnetic actuator with a high-strength coil to generate a strong enough electromagnetic force. On this basis, both numerical and experimental studies were performed to investigate the welding behavior of a 6061 aluminum alloy tube and a 304 stainless steel tube with 110 mm diameter and 3 mm thickness. Finally, a mechanical test and scanning electron microscope (SEM) were used to verify the joining quality, and the results show that the metallurgical bonding occurred between the two tubes. The presented optimization method and tool design could be of significance to the practical applications of MPW technology.
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Acknowledgments
This work was supported by the National Key Research and Development Program of China (Grant No. 2016YFA0401701), the National Basic Research Program of China (Grant No. 2011CB012801), and Young Elite Scientists Sponsorship Program by CAST (YESS, 2018QNRC001).
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Li, X. et al. (2021). Design and Fabrication of a High-Performance Magnetic Actuator for Magnetic Pulse Welding of Metal Tubes with Large Diameters. In: Daehn, G., Cao, J., Kinsey, B., Tekkaya, E., Vivek, A., Yoshida, Y. (eds) Forming the Future. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-030-75381-8_107
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DOI: https://doi.org/10.1007/978-3-030-75381-8_107
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