Magnetic pulse welding: Targeted manipulation of weld seam formation

• Applicants: Professor Dr.-Ing. Eckhard Beyer; Professor Dr.-Ing. A. Erman Tekkaya
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing ; Production Automation and Assembly Technology
• Term: from 2012 to 2020
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 227652982

Magnetic Pulse Welding (MPW) is a technology that allows for joining dissimilar materials due to high speed deformation and collision. In the first two funding periods of the priority program 1640, the joining mechanism and the key parameters for the production of long weld seams were investigated. On this basis, the focus in the third period of the collaborative research project is on the targeted intensification of the joining mechanism. Furthermore, measurement instruments for process control and prediction of the weld quality will be developed and tested. The duration of the magnetic pressure was identified as one of the major parameters. The influence of different pressure versus time plots on the forming behavior of the flyer will be studied. Therefore, the continuation of the successful cooperation between the Institute of Forming Technology and Lightweight Construction (IUL) at TU Dortmund university and the Institute of Manufacturing Technology (IF) at TU Dresden university is intended. This constellation offers advantages, since both institutes possess complementary pulse generators for the creation of discharging pulses with high and low frequencies. The complementary expertise of both institutes, forming and joining technology by IUL and joining technology and microstructure by IF, guarantee the success within the project procedure, supported by the cooperation with Fraunhofer IWS. The positive effect of thick and ductile coatings on the joint formation was discovered during the second period. The objective for the next period is to identify the material properties that are responsible for this phenomenon, e.g. the damping behavior of the coatings. Therefore, the established cooperation with the subgroup A4 will be extended. Additionally, the results will be transferred to achieve welding between parts with brittle coatings or additively manufactured samples. The contactless characterization of MPW seams through ultrasonic technology will be studied during the cooperation with the subgroup A2. Furthermore, the optical measurement of the flyer deformation will be used as an inline-process monitoring. After completion of the project, the basis for the further process adjustment close to the requirements of industrial users will be laid.

• DFG Programme: Priority Programmes
• Subproject of: SPP 1640: Joining by Plastic Deformation
• Co-Investigator: Professor Dr.-Ing. Noomane Ben Khalifa