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Metals
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Advances in Impulse Manufacturing
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Advances in Impulse Manufacturing

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Welding and Joining".

Deadline for manuscript submissions: closed (31 July 2023) | Viewed by 6534

Special Issue Editor

Dr. Taeseon Lee

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Incheon National University, 119 Academy-ro, Yeonsu-gu, Incheon 22012, Republic of Korea
Interests: novel manufacturing processes; impact welding; solid-state welding; resistance spot welding; welding metallurgy
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metalworking using a high strain rate can benefit many aspects of manufacturing and provide solutions to numerous challenges within the industry. For example, impact welding technologies such as vaporizing foil actuator welding enable the joining of dissimilar materials without significant structural modifications. Electromagnetic forming is another example, not requiring direct contact with the workpiece while extending the forming limits of several materials.

This Special Issue is devoted to addressing the recent development of impulse-based manufacturing technologies such as impact welding, impulse forming, and shock peening by means of explosives, electromagnetic fields, vaporizing foils, and pulsed lasers. Research articles are expected to either report on the state-of-the-art applications of impulse manufacturing or contributing to the understanding of their associated fundamental principles. Original research articles and reviews are welcome, and I look forward to receiving your contributions.

Dr. Taeseon Lee
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • impact welding
  • magnetic pulse welding
  • explosive welding
  • vaporizing foil actuator
  • electromagnetic forming
  • explosive forming
  • laser shock peening
  • laser impact welding

Published Papers (4 papers)

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Research

16 pages, 7324 KiB  
Article
Process Development and Analysis of Electromagnetic Multi-Spot Joining of AA5052 Sheets
by Ummed Singh, Ashish Rajak and Taeseon Lee
Metals 2023, 13(4), 729; https://doi.org/10.3390/met13040729 - 7 Apr 2023
Viewed by 1171
Abstract
In this study, two sheets of AA5052 are joined with the high-strain-rate multi-spot joining process using an electromagnetic system. While producing a single spot joint by electromagnetic joining (EMJ) is common, the distribution and application of the pressure can be modified by the [...] Read more.
In this study, two sheets of AA5052 are joined with the high-strain-rate multi-spot joining process using an electromagnetic system. While producing a single spot joint by electromagnetic joining (EMJ) is common, the distribution and application of the pressure can be modified by the design of the coil and spacers to make multiple joints at once. When a preformed dimple is used to provide the standoff distance, it can eliminate the need for spacers and provide good aesthetics for the final product. In the current study, a joint design is developed to provide three spot joints coincidentally by a single discharge of a capacitor bank. For the experiment, four distinctive discharge energies were used for joining: 7, 8, 9, and 10 kJ. The most successful joint sample was made by 8 kJ and was tested for mechanical properties. The cross-section was observed in order for us to understand the joint quality produced by the process. It was found that the ”I”-shaped rectangular coil produces a variable magnetic flux, leading to different flyer deformation variations in the joint geometry. At the centre of the ”I” coil, the minimum flux was predicted, leading to lesser sheet forming, hence a weaker centre-spot joint strength. Further, a numerical study is performed to find the Von Mises stresses, equivalent plastic strain, impact velocity, and impact pressure on the sheets. This manuscript provides new information regarding coil designing and the changes that could be further made to improve the electromagnetic sheet multi-spot joining process. Full article
(This article belongs to the Special Issue Advances in Impulse Manufacturing)
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14 pages, 4557 KiB  
Article
Microstructure and Properties of Multilayer Niobium-Aluminum Composites Fabricated by Explosive Welding
by Yulia N. Malyutina, Alexander G. Anisimov, Albert I. Popelyukh, Vasiliy S. Lozhkin, Anatoly A. Bataev, Ivan A. Bataev, Yaroslav L. Lukyanov and Vladimir V. Pai
Metals 2022, 12(11), 1950; https://doi.org/10.3390/met12111950 - 15 Nov 2022
Cited by 5 | Viewed by 1477
Abstract
In this study, a layered composite material consisting of alternating aluminum and niobium layers and cladded on both sides with titanium plates was obtained by explosive welding. Microstructure of the composite was thoroughly studied using scanning electron microscopy (SEM) and transmission electron microscopy [...] Read more.
In this study, a layered composite material consisting of alternating aluminum and niobium layers and cladded on both sides with titanium plates was obtained by explosive welding. Microstructure of the composite was thoroughly studied using scanning electron microscopy (SEM) and transmission electron microscopy (TEM), as well as by energy dispersive X-ray spectroscopy (EDX) and electron backscattered diffraction (EBSD). Microhardness measurements, tensile test, and impact strength test were carried out to evaluate the mechanical properties of the composite. Formation of mixing zones observed near all interfaces was explained by local melting and subsequent rapid solidification. Mixing zones at Nb/Al interfaces consisted of metastable amorphous and ultrafine crystalline phases, as well as NbAl3 and Nb2Al equilibrium phases. Niobium grains near the interface were significantly elongated, while aluminum grains were almost equiaxed. Crystalline grains inside the mixing zones did not have a distinct crystallographic texture. Microhardness of Al/Nb mixing zones was in the range 546–668 HV, which significantly exceeds the microhardness of initial materials. Tensile strength and impact strength of the composite were 535 MPa and 82 J/cm2, respectively. These results confirm the high bonding strength between the layers. Full article
(This article belongs to the Special Issue Advances in Impulse Manufacturing)
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22 pages, 9967 KiB  
Article
Deformation Behavior and Connection Mechanism of EMP Connections in Aluminum Pipe Joints
by Haiping Yu, Boyang Ma, Yihan He and Yang Qi
Metals 2022, 12(11), 1892; https://doi.org/10.3390/met12111892 - 4 Nov 2022
Cited by 1 | Viewed by 1273
Abstract
The joint is a key component of the aviation piping system, with severe performance requirements and better requirements for connection technology. With a focus on the manufacturing demand of AA6061 aerospace pipe joints, as well as the characteristics of EMP forming technology, this [...] Read more.
The joint is a key component of the aviation piping system, with severe performance requirements and better requirements for connection technology. With a focus on the manufacturing demand of AA6061 aerospace pipe joints, as well as the characteristics of EMP forming technology, this paper investigates the deformation behavior of the EMP forming on AA6061 aerospace pipe joints, the influence of process parameters on the deformation behavior, and the deformation mechanism of the tube wall. The results show that under the conditions of this paper, with an increase in the initial tube-sleeve gap and discharge voltage, the degree of local deformation of the AA6061 tube wall and the trench embedding rate increase. Keeping the width and depth of the grooves as 1.14 mm and 0.23 mm, the embedding rate of the grooves is less than 85% under the clearance conditions of 0.11 mm and 0.5 mm, while the lowest voltage for the embedding rate of the grooves to reach more than 85% under the clearance conditions of 1 mm, 1.5 mm and 2 mm is 7 kV, 6 kV, and 5 kV, respectively. The metallographic organization of the deformation area shows that the tube is deformed by the intense shear at the edge of the groove of the tube sleeve, thereby showing streamlined organization characteristics and deformation characteristics. The electromagnetic pulse forming process of the AA6061 tube is mainly divided into two stages: free bulging and local deformation; the inertia of high-rate deformation causes the groove filling to exhibit volume deformation characteristics in the local deformation stage. Full article
(This article belongs to the Special Issue Advances in Impulse Manufacturing)
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Graphical abstract

19 pages, 5029 KiB  
Article
Comprehensive Weldability Criterion for Magnetic Pulse Welding of Dissimilar Materials
by Angshuman Kapil, P. Mastanaiah and Abhay Sharma
Metals 2022, 12(11), 1791; https://doi.org/10.3390/met12111791 - 23 Oct 2022
Cited by 4 | Viewed by 1879
Abstract
Despite its exceptional ability to join dissimilar materials and environmental friendliness, several challenges must be addressed in magnetic pulse welding (MPW). The conventional weldability criterion (i.e., minimum impact velocity) is analytically calculated as a function of material properties without considering the geometry of [...] Read more.
Despite its exceptional ability to join dissimilar materials and environmental friendliness, several challenges must be addressed in magnetic pulse welding (MPW). The conventional weldability criterion (i.e., minimum impact velocity) is analytically calculated as a function of material properties without considering the geometry of electromagnetic coil, electrical and physical parameters, making the minimum impact velocity a necessary but not sufficient condition for a sound MPW joint. A new weldability criterion, namely effective impact velocity, is proposed, which overcomes the conventional weldability criterion’s limitations. The effective impact velocity can be inversely modelled to identify shop-floor relevant process parameters and it eliminates the need to fabricate several coils in the process and product proving stages. The proposed approach is demonstrated by a case study on tubular welding of Aluminium and SS304. The weld’s soundness produced with computed process parameters was corroborated by experimental observations on lap shear tests, hardness measurements, optical and scanning electron microscopy, and surface energy dispersive spectroscopy mapping. This investigation is expected to pave the way for developing the process window for MPW of several material combinations, with high cost and time savings. Full article
(This article belongs to the Special Issue Advances in Impulse Manufacturing)
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