Magnetic Pulse Welding and Spot Welding with Improved Coil Efficiency—Application for Dissimilar Welding of Automotive Metal Alloys
Lightweight structures in the automotive and transportation industry are increasingly researched. Multiple materials with tailored properties are integrated into structures via a large spectrum of joining techniques. Welding is a viable solution in mass scale production in an automotive sector still...
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doaj-56a5bc8b559346788f7271c3a1108d942020-11-25T02:44:53ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942020-07-014696910.3390/jmmp4030069Magnetic Pulse Welding and Spot Welding with Improved Coil Efficiency—Application for Dissimilar Welding of Automotive Metal AlloysChady Khalil0Surendar Marya1Guillaume Racineux2Research Institute in Civil and Mechanical Engineering (GeM, UMR 6183 CNRS), Ecole Centrale de Nantes, 1 rue de la Noë, F-44321 Nantes, FranceResearch Institute in Civil and Mechanical Engineering (GeM, UMR 6183 CNRS), Ecole Centrale de Nantes, 1 rue de la Noë, F-44321 Nantes, FranceResearch Institute in Civil and Mechanical Engineering (GeM, UMR 6183 CNRS), Ecole Centrale de Nantes, 1 rue de la Noë, F-44321 Nantes, FranceLightweight structures in the automotive and transportation industry are increasingly researched. Multiple materials with tailored properties are integrated into structures via a large spectrum of joining techniques. Welding is a viable solution in mass scale production in an automotive sector still dominated by steels, although hybrid structures involving other materials like aluminum are becoming increasingly important. The welding of dissimilar metals is difficult if not impossible, due to their differential thermo mechanical properties along with the formation of intermetallic compounds, particularly when fusion welding is envisioned. Solid-state welding, as with magnetic pulse welding, is of particular interest due to its short processing cycles. However, electromagnetic pulse welding is constrained by the selection of processing parameters, particularly the coil design and its life cycle. This paper investigates two inductor designs, a linear (I) and O shape, for the joining of sheet metals involving aluminum and steels. The O shape inductor is found to be more efficient both with magnetic pulse (MPW) and magnetic pulse spot welding (MPSW) and offers a better life cycle. Both simulation and experimental mechanical tests are presented to support the effect of inductor design on the process performance.https://www.mdpi.com/2504-4494/4/3/69magnetic pulse welding, spot welds, linear coils, shear lap test, automotive alloys, numerical analysis, LS-DYNA |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Chady Khalil Surendar Marya Guillaume Racineux |
spellingShingle |
Chady Khalil Surendar Marya Guillaume Racineux Magnetic Pulse Welding and Spot Welding with Improved Coil Efficiency—Application for Dissimilar Welding of Automotive Metal Alloys Journal of Manufacturing and Materials Processing magnetic pulse welding, spot welds, linear coils, shear lap test, automotive alloys, numerical analysis, LS-DYNA |
author_facet |
Chady Khalil Surendar Marya Guillaume Racineux |
author_sort |
Chady Khalil |
title |
Magnetic Pulse Welding and Spot Welding with Improved Coil Efficiency—Application for Dissimilar Welding of Automotive Metal Alloys |
title_short |
Magnetic Pulse Welding and Spot Welding with Improved Coil Efficiency—Application for Dissimilar Welding of Automotive Metal Alloys |
title_full |
Magnetic Pulse Welding and Spot Welding with Improved Coil Efficiency—Application for Dissimilar Welding of Automotive Metal Alloys |
title_fullStr |
Magnetic Pulse Welding and Spot Welding with Improved Coil Efficiency—Application for Dissimilar Welding of Automotive Metal Alloys |
title_full_unstemmed |
Magnetic Pulse Welding and Spot Welding with Improved Coil Efficiency—Application for Dissimilar Welding of Automotive Metal Alloys |
title_sort |
magnetic pulse welding and spot welding with improved coil efficiency—application for dissimilar welding of automotive metal alloys |
publisher |
MDPI AG |
series |
Journal of Manufacturing and Materials Processing |
issn |
2504-4494 |
publishDate |
2020-07-01 |
description |
Lightweight structures in the automotive and transportation industry are increasingly researched. Multiple materials with tailored properties are integrated into structures via a large spectrum of joining techniques. Welding is a viable solution in mass scale production in an automotive sector still dominated by steels, although hybrid structures involving other materials like aluminum are becoming increasingly important. The welding of dissimilar metals is difficult if not impossible, due to their differential thermo mechanical properties along with the formation of intermetallic compounds, particularly when fusion welding is envisioned. Solid-state welding, as with magnetic pulse welding, is of particular interest due to its short processing cycles. However, electromagnetic pulse welding is constrained by the selection of processing parameters, particularly the coil design and its life cycle. This paper investigates two inductor designs, a linear (I) and O shape, for the joining of sheet metals involving aluminum and steels. The O shape inductor is found to be more efficient both with magnetic pulse (MPW) and magnetic pulse spot welding (MPSW) and offers a better life cycle. Both simulation and experimental mechanical tests are presented to support the effect of inductor design on the process performance. |
topic |
magnetic pulse welding, spot welds, linear coils, shear lap test, automotive alloys, numerical analysis, LS-DYNA |
url |
https://www.mdpi.com/2504-4494/4/3/69 |
work_keys_str_mv |
AT chadykhalil magneticpulseweldingandspotweldingwithimprovedcoilefficiencyapplicationfordissimilarweldingofautomotivemetalalloys AT surendarmarya magneticpulseweldingandspotweldingwithimprovedcoilefficiencyapplicationfordissimilarweldingofautomotivemetalalloys AT guillaumeracineux magneticpulseweldingandspotweldingwithimprovedcoilefficiencyapplicationfordissimilarweldingofautomotivemetalalloys |
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