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Metals
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High Power Pulsed Processes for Welding and Forming of Metallic...
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High Power Pulsed Processes for Welding and Forming of Metallic Materials

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 2022) | Viewed by 10669

Special Issue Editor

Prof. Dr. Guillaume Racineux

E-Mail Website
Guest Editor
Ecole Centrale Nantes, Research Institute in Civil Engineering and Mechanics (GeM), 1 rue de la Noë, 44321 Nantes, CEDEX 3, France
Interests: solid-state welding; high-power pulse process; magnetic pulse welding crimping and forming; electrohydraulic forming
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

High power pulsed processes, whether by explosion, electro-hydraulic discharge, magnetic pulse, or vaporizing foil actuators, have many advantages for applications as diverse as the welding of similar and dissimilar materials, crimping, large- and small-dimensions parts forming, cutting, characterization of the dynamic behavior of materials, etc. However, many locks—scientific or technological—and a lack of knowledge of these processes mean that their application in industry remains limited.

In this Special Issue of the journal Metal, which we hope will be useful to both industry and researchers, we plan to bring together a set of contributions that present the state of the art of high power pulsed processes. We want to place special attention on:

- The presentation of the processes from both scientific and technological perspectives;

- The presentation of the specific advantages of these processes by drawing comparisons with other technologies;

- The presentation of original applications;

- The presentation of scientific and technological locks.

Prof. Guillaume Racineux
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

  • high power pulsed processes
  • explosion forming
  • electro-hydraulic forming
  • magnetic pulse welding
  • magnetic pulse forming
  • vaporizing foil actuators welding

Published Papers (5 papers)

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Research

24 pages, 5990 KiB  
Article
Comparative Analysis of Electrohydraulic and Electromagnetic Sheet Metal Forming against the Background of the Application as an Incremental Processing Technology
by Thomas Heggemann, Verena Psyk, Annika Oesterwinter, Maik Linnemann, Verena Kräusel and Werner Homberg
Metals 2022, 12(4), 660; https://doi.org/10.3390/met12040660 - 12 Apr 2022
Cited by 6 | Viewed by 2648
Abstract
High-speed forming processes such as electromagnetic forming (EMF) and electrohydraulic forming (EHF) have a high potential for producing lightweight components with complex geometries, but the forming zone is usually limited to a small size for equipment-related reasons. Incremental strategies overcome this limit by [...] Read more.
High-speed forming processes such as electromagnetic forming (EMF) and electrohydraulic forming (EHF) have a high potential for producing lightweight components with complex geometries, but the forming zone is usually limited to a small size for equipment-related reasons. Incremental strategies overcome this limit by using a sequence of local deformations to form larger component areas gradually. Hence, the technological potential of high-speed forming can be exploited for large-area components too. The target-oriented process design of such incremental forming operations requires a deep understanding of the underlying electromagnetic and electrohydraulic forming processes. This article therefore analyzes and compares the influence of fundamental process parameters on the acting loads, the resulting course of deformation, and the forming result for both technologies via experimental and numerical investigations. Specifically, it is shown that for the EHF process considered, the electrode distance and the discharge energy have a significant influence on the resulting forming depth. In the EHF process, the largest forming depth is achieved directly below the electrodes, while the pressure distribution in the EMF depends on the fieldshaper used. The energy requirement for the EHF process is comparatively low, while significantly higher forming speeds are achieved with the EMF process. Full article
(This article belongs to the Special Issue High Power Pulsed Processes for Welding and Forming of Metallic Materials)
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18 pages, 1914 KiB  
Article
Analytical Estimation of Electromagnetic Pressure, Flyer Impact Velocity, and Welded Joint Length in Magnetic Pulse Welding
by Rishabh Shotri, Koen Faes, Guillaume Racineux and Amitava De
Metals 2022, 12(2), 276; https://doi.org/10.3390/met12020276 - 02 Feb 2022
Cited by 6 | Viewed by 1538
Abstract
Magnetic pulse welding involves the joining of two metallic parts in a solid state by the use of a short and intense electromagnetic impulses and the resulting impact between the parts. The coalesced interface undergoes visco-plastic deformation at a high strain rate and [...] Read more.
Magnetic pulse welding involves the joining of two metallic parts in a solid state by the use of a short and intense electromagnetic impulses and the resulting impact between the parts. The coalesced interface undergoes visco-plastic deformation at a high strain rate and exhibits a wavy shape at a microscopic scale. A practical estimation of the electromagnetic pressure, impact velocity and welded joint length as a function of the process conditions and the electromagnetic coil geometry is required but currently not available. Three novel analytical relations for the estimation of the electromagnetic pressure, impact velocity, and welded joint length for magnetic pulse welding of tubes and sheets, are presented. These relations were developed systematically, following a dimensional analysis, and validated for a wide range of conditions from independent literature. The comparison of the analytically computed results and the corresponding values reported in the literature has illustrated that the proposed analytical relations can be used for the estimation of the electromagnetic pressure and impact velocity for the magnetic pulse welding of tubes and sheets with a good level of confidence. The analytically calculated results for the welded joint length show a little discrepancy with the corresponding experimentally measured values. Further investigations and more experimentally measured results are required to arrive at a more comprehensive analytical relation for the prediction of welded joint length. Full article
(This article belongs to the Special Issue High Power Pulsed Processes for Welding and Forming of Metallic Materials)
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19 pages, 8522 KiB  
Article
Magnetic Pulse Hybrid Joining of Polymer Composites to Metals
by Chady Khalil, Surendar Marya and Guillaume Racineux
Metals 2021, 11(12), 2001; https://doi.org/10.3390/met11122001 - 11 Dec 2021
Cited by 3 | Viewed by 2139
Abstract
To lighten their vehicles, car manufacturers are inclined to substitute steel structures with aluminum alloys or composites parts. They are then faced with the constraints inherent to dissimilar (galvanized steel/aluminum) or hybrid (metal/composite) assemblies. Recent developments in magnetic pulse welding seems to offer [...] Read more.
To lighten their vehicles, car manufacturers are inclined to substitute steel structures with aluminum alloys or composites parts. They are then faced with the constraints inherent to dissimilar (galvanized steel/aluminum) or hybrid (metal/composite) assemblies. Recent developments in magnetic pulse welding seems to offer a viable route. Very fast, this process can be robotized and generates a very localized heating system which limits the formation of intermetallic and damage the composite. Low energy consumption, without filler metal or smoke it is recognized as an environmentally friendly process. In this paper, electromagnetic pulse welding is exploited to assemble polymer composite to metals. Two techniques, a metallic insert in polymer composite or an external patch, have been tested with possible design considerations. Full article
(This article belongs to the Special Issue High Power Pulsed Processes for Welding and Forming of Metallic Materials)
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11 pages, 1951 KiB  
Article
Critical Assessment of the Electric Effect in Electric Arc Welding
by Rongshan Qin
Metals 2021, 11(12), 1917; https://doi.org/10.3390/met11121917 - 27 Nov 2021
Cited by 2 | Viewed by 1783
Abstract
This work provides a critical assessment of electric effects on the microstructure evolution at the heat-affected zone in electric arc welding. Electric effects are the interactions between electromagnetic fields and materials’ microstructures. They differ from the arc effect and the Joule heating effect [...] Read more.
This work provides a critical assessment of electric effects on the microstructure evolution at the heat-affected zone in electric arc welding. Electric effects are the interactions between electromagnetic fields and materials’ microstructures. They differ from the arc effect and the Joule heating effect by providing an alternative contribution to nucleation, grain growth, recrystallisation and tempering. The influence of the electric effect on grain size, defects, anisotropic properties, precipitates and residual stress has been examined kinetically and thermodynamically. The use of adaptable electric current densities, pulse durations, pulse frequencies and electrode movements is suggested to achieve desirable microstructures and mechanical properties for the weldments. Full article
(This article belongs to the Special Issue High Power Pulsed Processes for Welding and Forming of Metallic Materials)
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13 pages, 9329 KiB  
Article
Influence of Copper Interlayers on the Magnetic Pulse Welding Process between Aluminum and Steel
by Joerg Bellmann, Kristina Roder, Martina Zimmermann, Eckhard Beyer, Lothar Kroll and Daisy Nestler
Metals 2021, 11(6), 868; https://doi.org/10.3390/met11060868 - 26 May 2021
Cited by 6 | Viewed by 1761
Abstract
Magnetic pulse welding (MPW) is a promising joining technology for the large-scale production of dissimilar metallic joints. Although the heat input is comparatively low, the temporary occurrence of high temperatures in the joining gap was found to play an important role during the [...] Read more.
Magnetic pulse welding (MPW) is a promising joining technology for the large-scale production of dissimilar metallic joints. Although the heat input is comparatively low, the temporary occurrence of high temperatures in the joining gap was found to play an important role during the joint formation. It is possible that the melting or even the boiling temperature of the involved materials will be exceeded, and fusion welding will occur. The purpose of this study is to investigate the influence of target materials with different thermal properties on the joint formation and weld seam characteristic. Therefore, MPW between steel targets and aluminum flyers was performed with and without copper coatings on steel. The lower melting temperature of copper compared to steel had no significant effect on the appearance of the mixed zones in the interface and the amount of molten target material or aluminum, respectively. Nevertheless, the comparison of the higher impact energies showed, that the copper interlayer can lead to a decrease in the weld length or a degradation of the weld quality due to an extended intermetallic phase formation or cracks. This result is important for the parameter adjustment of magnetic pulse welding processes. Full article
(This article belongs to the Special Issue High Power Pulsed Processes for Welding and Forming of Metallic Materials)
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