Workers exposure to electromagnetic fields from welding. Introduction electromagnetic pulse welding is an innovative solidstate welding technology that belongs to the group of pressure welding processes. Electromagnetic pulse emp protection and resilience. Read online electromagnetic pulse emp protection and resilience. Magnetic pulse welding is a solid state cold welding generated by high speed collision between two metals at room temperature tubular elements up to o125mm or sheet metal. Electromagnetic pulse welding of fluid joints the boeing. Industrialisation of electromagnetic pulse technology. An emp or e lectro m agnetic p ulse is a wave of electromagnetic radiation. Abstractelectromagnetic pulse welding can be categorised as a fast, precise, and contactless solidstate joining process. When applied to aluminium and copper, electromagnetic pulse welding opens the possibility of entirely suppressing, or at least minimising, the intermetallic phases of cracking susceptible microstructures. Electromagnetic pulse forming of carbon steel sheet metal r.
Electromagnetic pulse welding of magnesium to aluminium. The mpw is sufficiently flexible to weld various shapes of components for different joint configurations such as half lap, overlap, cross lap and end lap section 2. In very large events an emp can cause electronic systems failures. Due to the ease of controlling magnetic fields, em technique is more suitable for joining axis symmetric components.
The objective of this work is to propose a magnetic pulse spot welding mpsw process with the aid of a field shaper for achieving the connecting of metal components. Jun 27, 2018 the objective of this work is to propose a magnetic pulse spot welding mpsw process with the aid of a field shaper for achieving the connecting of metal components. Coupled electromagneticstructural simulation of magnetic pulse welding angshuman kapil and abhay sharma abstract the present study deals with the coupled magneticstructural analysis of magnetic pulse welding mpw process applied on a tubular workpiece. Highaltitude nuclear detonations and electromagnetic bombs can generate emp that. For achieving the successful weldment and using this process, the design of working coil is the most important factor. Magnetic pulse technology mpt forming welding is a highspeed metal processing technology which uses electromagnetic force to form or weld various materials, and is especially good for aluminum and copper alloys that have a high electrical conductivity. Magnetic pulse welding, a high speed joining process using electromagnetic forces, because of clean and multimaterial operation has a wide range of possibilities for further development and application. The electrical energy stored in the magnetic pulse power source is discharged.
Electromagnetic pulse welding has been produced as one technique for impact welding. Electromagnetic pulse welding epw is an effective way to realize the connection of two different kinds of metal. Electromagnetic energy transmission in magnetic pulse welding of alcu sheets using 1, 3, 4 and 6 turn flat coils tomokatsu aizawa tokyo metropolitan college of technology 11040, higashiohi, shinagawaku, tokyo 1400011, japan email. This study shows the transmission efficiency of the electromagnetic energy which move from the bank to the coil.
Distribution of electromagnetic force of square working. By utilizing this coil, joints of up to 120 mm can be created within a single pulse process. Once it was widely thought to be an exceptional innovative welding solution, the magnetic pulse welding, dragged the related manufacturing industries and particularly automobile companies for its complex assembly solutions in early 2000s. Effect of the welding parameters on the structural and. Electromagnetic pulse forming of carbon steel sheet metal. Electromagnetic energy transmission in magnetic pulse.
The electromagnetic pulse technology empt provides noncontact processes for joining, welding, forming and cutting of metals. Dec 07, 2010 the present invention is related to u. For empt processing electromagnetic coils are used, to which a short but very highpower electric current is applied from a pulse generator. Process equipment joint examples for electromagnetic pulse welding of flat sheets fraunhofer iws has developed a special flat coil. Figure 3 shows typical magnetic pulse welding architecture with overlap configuration used to weld a core clad combination. Process insights by high speed imaging and numerical simulation c. On the other hand, solidstate welding techniques such as electromagnetic pulse welding allow for joining to occur below the melting temperature 17. A large one could knock out power or kill electronic. Pdf electromagnetic energy transmission in magnetic pulse.
Dec 23, 2016 electromagnetic welding emw is a highspeed joining technique that is used to join similar or dissimilar metals, as well as metals to nonmetals. Idaho national laboratory inl was chosen to conduct the emp study for doeoe. Strategies, protections, and mitigations for the electric. Magnetic pulse welding and forming are unique high speed. Unlike conventional joining processes, the weld interface does not melt, thus keeping the material properties intact.
In the present study, a thermomechanically coupled dynamic model has been developed to quantitatively resolve the high. Its mechanism is similar to explosion welding technique. Magnetic pulse welding mpw applies the electromagnetic principles postulated in the xixth century and later demonstrated. Coupled electromagnetic structural simulation of magnetic. Magnetic pulse welding is a solid state cold welding. Magnetic pulse welding diagram equipment application. Magnetic pulse and electrohydraulic processes for forming. Magnetic pulse welding on the cutting edge of industrial. The workpiece is reshaped by high intensity pulsed magnetic fields that induce a current in the workpiece and a corresponding repulsive magnetic field, rapidly repelling portions of the workpiece. A metallurgically formed fluid circuit joint includes a hollow fitting 298, a tubular conduit 297, and a metallurgically formed tubefitting mesh 296. Electromagnetic pulse welding of fluid joints download pdf info publication number us7847223b2. Magnetic pulse technology mpt formingwelding is a highspeed metal processing technology which uses electromagnetic force to form or weld various materials, and is especially good for aluminum and copper alloys that have a high electrical conductivity.
This technique uses electromagnetic force to mainly join conductive materials. The study investigates the various criteria required for a successful weld between the. An emp or hemp high altitude emp usually occurs in a broadband nature. Extremely high velocity and strain rate involved in.
The process can be used to join tubular 1 and sheet metals 2, placed in the overlap. Although this technique has been implemented by some giant manufacturers for various joining tasks, the process still has not been well adopted by industries. The past research work in this field shows that the auto ignition of aluminum powder with a particle size of under 10 m can already happen at. Electromagnetic pulse technology empt for joining, welding. Emp can also be produced from nonnuclear sources, such as electromagnetic bombs, or ebombs. Electromagnetic energy transmission in magnetic pulse welding. Mps electromagnetic magnetic pulse forming and welding.
Electromagnetic pulse welding is an innovative solidstate welding technology that belongs to the group of pressure welding processes. Pdf electromagnetic energy transmission in magnetic. The type of welding process which uses magnetic forces to weld two workpieces together is called magnetic pulse welding. Electromagnetic pulse technology empt provides noncontact process for joining, welding, forming and cutting metals with great potential to join similar and dissimilar materials besides the conventional welding techniques often used in the industry. The quality of an electromagnetic pulse weld is strongly affected by a variety of interacting physical phenomena including large plastic deformation, materials mixing, localised heating and rapid cooling, and possible localised melting and interfacial cracks and void. The sheets alcu with a gap are overlapped and fixed on the coil. Jun 14, 2015 magnetic pulse forming and welding by mps5.
The aim of the legislation is to protect workers from the risks associated with electromagnetic fields, so it is mainly applicable to manual processes such as resistance welding using pedestal welders, portable spot welding guns and arc welding. Us20080036204a1 electromagnetic pulse welding of fluid. Electromagnetic pulse welding empw is a technique for welding of metals by means of plastic deformation generated by a repulsive force on account of the interaction between the magnetic field of the coil and the current induced in the workpiece. A hemp is a high amplitude short duration, broadband pulse of electromagnetic energy. With special coil design, it can also be used to join mg to al sheets. Us7847223b2 electromagnetic pulse welding of fluid. Pdf magnetic pulse welding mpw method for dissimilar. An emp does not directly hurt people, but an emp interacts with power lines, metal, conductive materials and electronics and causes power spikes. Magnetic pulse welding process, one of high speed welding processes, uses electromagnetic force from discharged current through a working coil which develops a repulsive force between the induced currents flowing parallel and in the opposite direction in the pipe to be welded. Magnetic pulse welding mpw is another noncontact solidstate welding process, completed in microsecond time using the lorentz force formed in magnetic fields as driving force 8.
Electromagnetic coupling exists between the coil and the al sheet near the coil. The magnetic field shaper that is placed between the metal components and an electromagnetic coil is used to concentrate the magnetic field around the weld zone and then enhance the generated lorentz force acting on the metal. Highspeed visualization of electromagnetic pulse welding. In recent years the process has been developed to meet highly demanding market needs involving dissimilar material joining, specially involving difficulttoweld materials. Magnetic pulse welding mpw method for dissimilar sheet metal joints. Oct 30, 2019 impact welding is a procedure which establishes metallurgical bonds, even between metals that are not similar. Electromagnetic em welding is based on application of amperes law. Impact welding is a procedure which establishes metallurgical bonds, even between metals that are not similar. Using aluminum alloys for automotive components could reduce vehicle body structure weight and using these alloys is receiving much attention. Numerical investigation of electromagnetic pulse welded. The auto ignition temperature of aluminum strongly depends on the particle size. Us7847223b2 us11865,452 us86545207a us7847223b2 us 7847223 b2 us7847223 b2 us 7847223b2 us 86545207 a us86545207 a us 86545207a us 7847223 b2 us7847223 b2 us 7847223b2 authority us. The magnetic field shaper that is placed between the metal components and an electromagnetic coil is used to concentrate the magnetic field around the weld zone and then enhance the generated lorentz force acting on the. The workpiece is reshaped by high intensity pulsed magnetic fields that induce a current in the workpiece and a corresponding repulsive magnetic field, rapidly repelling.
Pdf magnetic pulse welding technology ahmad jassim. It was observed that empw generated an annular or ringshaped bonding area, with weld zones and a central nonweld zone when viewed. The tubefitting mesh 296 includes a fitting portion of the hollow fitting 298 and a tube portion of the tubular conduit 297 that is electromagnetically formed with the fitting portion. All books are in clear copy here, and all files are secure so dont worry about it. The aim of this study was to identify and analyze the fatigue fracture characteristics of dissimilar al 6061 to cu uns c1 lap joints made with ultrafast electromagnetic pulse welding empw via fractography, stress analysis and finite element simulation. One of the threats oe is concerned about is a highaltitude electromagnetic pulse hemp from a nuclear explosion and electromagnetic pulse emp or an early time e1 pulse which can be generated by emp weapons. Electromagnetic welding emw is a highspeed joining technique that is used to join similar or dissimilar metals, as well as metals to nonmetals.
A high pulse current from a capacitor bank is discharged through an insulated flat coil for magnetic abstract pulse welding of sheets. Iwsnewsletter 012016 electromagnetic pulse welding an. A hemp is a high amplitude short duration, broadband pulse of. Groche1 1 institute for production engineering and forming machines, tu darmstadt, germany abstract most researches on the mechanisms of impact welding in general base their results on. Us7847223b2 electromagnetic pulse welding of fluid joints.
Fracture characteristics and analysis in dissimilar cual. Electromagnetic pulse welding of two aluminum sheets with left and without right inert gas atmosphere. Electromagnetic forming em forming or magneforming is a type of high velocity, cold forming process for electrically conductive metals, most commonly copper and aluminium. Review on electromagnetic welding of dissimilar materials. Magnetic pulse welding mpw is another noncontact solidstate welding process, completed in microsecond time using the lorentz force formed in magnetic fields. Coupled electromagnetic structural simulation of magnetic pulse welding angshuman kapil 1, abhay sharma 2 1 indian institute of technology, hyderabad, 502205, email. Weldability of the combined welded joints is evaluated, and fields of application of this process are given. Interfacial microstructures and temperatures in aluminium. Electromagnetic pulse welding can be categorised as a fast, precise, and contactless solidstate joining process. Method of magnetic pulse welding an end fitting to a driveshaft tube of. Magnetic pulse welding is based on a very short electromagnetic pulse pdf available september 2011. Electromagnetic pulse welding facility consists of power supply, hmi control, capacitor banks, trigger generators, spark gaps and empw actuators figure 2 shows the general outlines of the magnetic pulse welding apparatus, which consists of a capacitor bank c and a spark gap switch g with a onelayer, e shaped flat coil. Electromagnetic pulse welding can be used for tubular and sheet applications, placed in the overlap configuration. Us20060208481a1 electromagnetic pulse welding of fluid.
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