Magnetic pulse welding of copper to steel tubes-Experimental investigation and process modelling

Magnetic pulse welding allows joining of metallic tubes by a short electromagnetic pulse and the resulting high strain rate impact and plastic deformation. Since melting of materials is avoided, magnetic pulse welding is an efficient method for joining of dissimilar materials. However, the process occurs very fast with little opportunity for real-time monitoring and control, which is also difficult due to the presence of a high amplitude electromagnetic field. A novel attempt is presented here to examine the underlying phenomena for magnetic pulse welding of copper flyer tubes to steel target tubes by computational process modeling and a focused experimental investigation. A coupled electromagnetic and mechanical finite-element model was created to compute the electromagnetic field and pressure distribution, and the progressive nature of flyer tube impact velocity on the target tube. The consequent progress of the angle of impact and contact length are examined for a range of standoff distances between the flyer and target tubes, the target tube wall thickness. The computed results are validated extensively with corresponding experimentally measured results. Overall, the coupled theoretical and experimental investigation provided a useful quantitative insight of magnetic pulse welding of copper and steel tubes, which is expected to help in the advancement of practical application of the process.