Thermal Effects in Dissimilar Magnetic Pulse Welding
Abstract
:1. Introduction
- Investigate the influence of the flyer kinetics on the material flow.
- Study the influence of different collision conditions on the formation and properties of the jet or “cloud of particles” (CoP) and the corresponding thermal conditions in the joining gap.
- Build up a temperature model for the welding interface, based on the heat input by the CoP.
2. Materials and Methods
2.1. Nomenclature
2.2. Experiments
2.3. Numerical Simulations
- The thermal energy of the CoP is responsible for the surface activation before both joining partners get into contact. In order to simplify the numerical model, this is assumed to be the only heat source. The heat input by plastic deformation after the collision is not considered in the model.
- The thermal energy of the CoP is equally distributed to both joining partner surfaces, which seems admissible for small collision angles.
- At the welding interface, just solid and liquid phases are present at the time of contact. If the surface temperature would lead to vaporization before contact, the material in the gaseous phase would be pressed out of the joining gap together with the CoP during MPW, provided a sufficient collision angle.
- The influence of the temperature on the materials’ densities, heat capacities and thermal conductivities is not considered in the simulations.
3. Results and Discussion
3.1. Effect of the Flyer Kinetics on the Material Flow
3.2. Characteristics of the “Cloud of Particles” (CoP)
3.3. Temperature Model
4. Research Highlights
- The experiments showed that jetting in the type of a strong material flow is not mandatory for a successful MPW process. A cloud of particles (CoP), which is ejected during the impact with lower velocities, enables welding, too. Compared to the “real” jet in the style of a massive material flow at higher impact velocities, the CoP cannot remove thick surface layers or facilitate welding with rough surfaces. In this case, an adapted surface preparation and cleaning process is essential to ensure a sufficient surface activation.
- The appearance of the CoP and its effect on the weld formation is determined by the prevalent collision conditions, especially the collision angle. This factor can be adjusted by various machine related factors and the part geometries. Vacuum experiments show that the CoP is established during the first metal to metal impact with a certain minimum impact velocity. Afterwards, it is compressed in the closing joining gap, successively heated up and finally ejected in welding direction.
- For small collision angles, the level of compression and the internal friction of the CoP are higher and, thus, the temperature in the joining gap increases. In this configuration, the CoP is finely distributed like a metal vapor, which activates the surfaces of the joining partners homogeneously and can be seen inside the flyer tube after the experiment. If the collision angle is increased, the temperature decreases and single macroscopic particles are ejected. These particles seem to have a reduced surface activation effect, compared to the finely dispersed metal vapor described previously and thus, inhibit welding.
- These findings allow for an optimization of the energy input during MPW. If a small collision angle is ensured, the initial impact velocity can be reduced. Thus, less mechanical energy is required for the forming process and the loading on the tool coils is reduced with positive effects on their lifetime.
- Normally, the MPW process is performed in ambient atmosphere, where the free CoP ejection is hindered by the surrounding air. This leads to a shock compression and sudden heat up of the gas and results in a very strong process glare. This strong lightning can be utilized for the quality assurance during industrial production [39].
- The numerical simulations of the surface temperatures of both joining partners revealed a strong influence of the waiting time between the end of the heat input by the CoP and the contact of both joining partners. Especially for dissimilar metal welding, this time needs to be very low to avoid solidification before the contact. This finding is important for the theory of liquid state bonding and in good correlation with the experimental results. Small collision angles, or gap closing times, respectively, are beneficial for the weld formation during MPW.
5. Patents
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Symbol | Parameter | Symbol | Parameter |
---|---|---|---|
A | Area | s | Thickness of the flyer tube |
b | Equivalent thickness of the molten layer | S | High voltage switch |
c | Heat capacity | t | Time |
C | Capacitance; Contact point | T | Temperature |
d | Distance to the impact location | tcon | Contact time |
E | Charging energy | tf,start | Flash appearance time |
fdischarge | Discharge frequency | TFly | Flyer temperature |
g | Initial joining gap | Tfus | Melting temperature |
I | Discharge current | theat | Heating time |
If | Intensity of the impact flash | timp | Impact time |
Imax | Maximum discharge current | TPar | Parent temperature |
k | Thermal conductivity | Tvap | Boiling temperature |
l | Length of welded zone | twait | Waiting time |
lc | Collision length | U | Voltage |
Li | Inner inductance of the pulse generator | V | Volume |
lw | Working length | vi | Impact velocity |
m | Mass | vi,r | Radial impact velocity |
p | Surrounding pressure | wc | Width of the coil concentration zone |
P | Heat input | z | Distance perpendicular to the steel surface |
pm | Magnetic pressure | α | Angle of inclined parent surface |
Q | Total heat input | γ | Damping coefficient of I(t) |
Qs | Heat input to each surface | ΔHfus | Enthalpy of fusion |
Ra | Mean roughness index | Δt | Gap closing time |
Ri | Inner resistance of the pulse generator | ρ | Density |
Flyer Part EN AW-6060 1, Quasi-Static Yield Strength Approximately 60 MPa 2 | Parent Part C45 (1.0503), Normalized, Quasi-Static Yield Strength Approximately 490 MPa 3, Surface Polished (Ra = 1) | ||
---|---|---|---|
Element | Weight % | Element | Weight % |
Mg | 0.35–0.6 | C | 0.42–0.5 |
Mn | ≤0.1 | Mn | 0.5–0.8 |
Fe | 0.1–0.3 | P | <0.045 |
Si | 0.3–0.6 | S | <0.045 |
Cu | ≤0.1 | Si | <0.4 |
Zn | ≤0.15 | Ni | <0.4 |
Cr | ≤0.05 | Cr | <0.4 |
Ti | ≤0.1 | Mo | <0.1 |
Setup | Unit | Bmax MPW 50/25 | EmGen |
---|---|---|---|
Capacitance | µF | 160 | 140 |
Inductance 1 | nH | 372 | 2700 |
Maximum charging energy | kJ | 32 | 40 |
Maximum charging voltage | kV | 20 | 24 |
Applied charging energy—E | kJ | 4.5–9.6 | 7.0–22.7 |
Discharge frequency 1—fdischarge | kHz | ~21 | ~9 |
Damping coefficient γ 1 | 1/s | 16,500 | 2700 |
Physical Quantity | Symbol | Unit | EN AW-6060 | C45 | Cu [31] |
---|---|---|---|---|---|
Density | ρ | kg/m3 | 2700 [32] | 7700 [24] | 8960 |
Heat capacity | c | J/kgK | 898 [32] | 470 [24] | 390 |
Thermal conductivity | k | W/mK | 210 [32] | 42.6 [24] | 384 |
Melting temperature | Tfus | °C | 659 [31], pure aluminum | 1536 [31], pure iron | 1083 |
Boiling temperature | Tvap | °C | 2467 [31], pure aluminum | 3070 [31], pure iron | 2595 |
Enthalpy of fusion | ΔHfus | kJ/kg | 356 [31], pure aluminum | 276 [31], pure iron | 213 |
Physical Quantity | Symbol | Unit | Value |
---|---|---|---|
Heat quantity at each surface | QS/A | J/m2 | 22,450 |
Heating time | theat | µs | 0.5 |
Waiting time | twait | µs | 0 |
Flyer material | - | - | EN AW-6060 |
Parent material | - | - | C45 |
Consideration enthalpy of fusion? | - | - | true |
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Bellmann, J.; Lueg-Althoff, J.; Schulze, S.; Hahn, M.; Gies, S.; Beyer, E.; Tekkaya, A.E. Thermal Effects in Dissimilar Magnetic Pulse Welding. Metals 2019, 9, 348. https://doi.org/10.3390/met9030348
Bellmann J, Lueg-Althoff J, Schulze S, Hahn M, Gies S, Beyer E, Tekkaya AE. Thermal Effects in Dissimilar Magnetic Pulse Welding. Metals. 2019; 9(3):348. https://doi.org/10.3390/met9030348
Chicago/Turabian StyleBellmann, Joerg, Joern Lueg-Althoff, Sebastian Schulze, Marlon Hahn, Soeren Gies, Eckhard Beyer, and A. Erman Tekkaya. 2019. "Thermal Effects in Dissimilar Magnetic Pulse Welding" Metals 9, no. 3: 348. https://doi.org/10.3390/met9030348