Effect of Conductivity of the Inner Rod on the Collision Conditions During a Magnetic Pulse Welding Process
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Date
2016-04-27
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Abstract
The Magnetic Pulse Welding (MPW) process involves a high speed collision between the
flyer and inner rod. Conductivity of the inner rod may play a significant role in the collision
speed and collision angle. The collision conditions were investigated with varying
conductivity of the inner rod in this study. Coupled mechanical-electromagnetic 3D
simulations were carried out using LS-DYNA package to investigate the effect of
conductivity of the inner rod on the collision patterns during the MPW process. The
simulation involves a welding process with a tube and a rod using a one turn coil with a
separate field shaper. The electrical conductivity was varied to a wide range to investigate
the influence on the collision condition. Moreover, in order to verify the independency of the
collision condition with the mechanical properties of the inner rod, two cases including
aluminum alloy AA2024-T351 and copper with appropriate Johnson-Cook parameters were
used for the rod. In the entire simulations aluminum alloy was used as the tube material. It
was identified that the impact velocity is almost consistent for each case and the impact
angles vary between negative and positive values according to the angular measurement
convention used in this study. Although, influence of the conductivity of the inner rod is not
significant for the investigated current flow while it may sometime delay the incidence of
collision at lower frequencies than the critical frequency (FCrit). Optimizing the collision
conditions in the MPW process can help to identify the suitable materials for prescribed
welding conditions.
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Keywords
magnetic pulse welding, collision velocity, numerical modelling