Can magnetic pulse welding be used in welding aluminium to steel?

Magnetic pulse welding has been successfully used in welding aluminium to steel. Also other dissimilar and similar metals that have been welded successfully (see table below). This joining technique is adaptable to a wide variety of electrical conductive materials. Less conductive materials require a higher energy.

What are the conditions for magnetic pulse welding?

A condition for magnetic pulse welding is that the material to be deformed needs to possess a good electrical conductivity. If this is not the case, the required energy to deform or weld the material increases. Another condition is that the surfaces to be joined need to be positioned in the overlap configuration.

What is electromagnetic pulse welding?

Electromagnetic pulse welding technology can achieve effective bonding of different metals without intermetallic compounds and heat-affected zones. Current research primarily focuses on bonding interface and strength, neglecting the fact that the strength of the joint is also related to the performance of the plate itself.

What equipment is used for magnetic pulse welding?

Equipment for magnetic pulse welding consists of the following components: a transformer coil, with which the frequency and amplitude of the electric current discharge can be adjusted. BWI has a test setup that allows to investigate the applicability of the process for certain applications.

Why is magnetic pulse welding a cold welding process?

The magnetic pulse welding process is also a "cold" welding process, the heat generation is very limited. This will create no heat-affected zone and the material properties in the weld zone are not changed. The absence of heat during the weld cycle allows to connect materials with a strongly different melting point.

How do magnetic fields affect welding?

Both currents (in the coil and in the external workpiece) induce magnetic fields, which oppose each other. The reaction forces between the opposing magnetic fields are forcing the external part towards the internal part at high velocity to cause welding. The impacting speed is more than 1000 km/h.