Investigation of Electromagnetic Pulse Welding for the Automated Production of Resource-Efficient Multi-Material Joints
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Date
2025-08-26
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Abstract
Electromagnetic pulse welding (EMPW) is a promising technology for the automated
production of multi-material joints made of high-strength aluminium alloys and steels and
is therefore capable of realising light-weight design by exploiting the potential of both
materials. The ongoing Design2Collide research project is investigating the potential
applications of EMPW in an industrial environment with the aim of reducing the limitations
associated with the use of the process. Its automation capability is demonstrated by
converting a state-of-the-art robotic production cell to join a demonstration assembly made
of steel (DC04) and aluminium (AA6016). Welding studies to derive process windows with
the best joint strengths are carried out using an EMPW system and a special model test rig
for collision welding. Reproducible attainment of ample joint strength is indicated by failure
of the base material AA6016 due to shearing, while the joint itself remains intact. To ensure
excellent joint properties, an in-line quality control method based on active thermography
is developed and integrated into the automated process. Initial stand-alone tests of the
developed method with the EMPW system show promising results for feasibility and
industrial qualification. The examination of the EMPW value chain is currently being
completed by the investigation of corrosion prevention and passivation systems for the
pre and post-treatment of materials and their impact on weldability, and by the improvement of
process simulation. For the latter, adapted material models are essential. Respective flow
curves have already been determined for the materials used at high strain rates of up to
104 1/s.
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Keywords
Electromagnetic Pulse Welding,, Emission Reduction, Lightweight Concepts, Multi-Material Design
Subjects based on RSWK
Elektromagnetisches Pulsschweißen, Werkstoffpaarung, Leichtbau, Emissionsverringerung, Fertigung