Investigation of Electromagnetic Pulse Welding for the Automated Production of Resource-Efficient Multi-Material Joints

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dc.contributor.authorKraus, S. O.
dc.contributor.authorGraß, M.
dc.contributor.authorBruder, J.
dc.contributor.authorPabst, C.
dc.contributor.authorHolz, J.
dc.contributor.authorWiedemann, J.
dc.contributor.authorFrodl, S.
dc.contributor.authorHeckmann, M.
dc.contributor.authorFrint, P.
dc.contributor.authorBöhm, S.
dc.contributor.authorGroche , P.
dc.date.accessioned2025-09-16T17:26:28Z
dc.date.available2025-09-16T17:26:28Z
dc.date.issued2025-08-26
dc.description.abstractElectromagnetic 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.en
dc.identifier.urihttp://hdl.handle.net/2003/43923
dc.identifier.urihttp://dx.doi.org/10.17877/DE290R-25691
dc.language.isoen
dc.relation.ispartof10th International Conference on High Speed Formingen
dc.subjectElectromagnetic Pulse Welding,en
dc.subjectEmission Reductionen
dc.subjectLightweight Conceptsen
dc.subjectMulti-Material Designen
dc.subject.ddc620
dc.subject.ddc670
dc.subject.rswkElektromagnetisches Pulsschweißen
dc.subject.rswkWerkstoffpaarung
dc.subject.rswkLeichtbau
dc.subject.rswkEmissionsverringerung
dc.subject.rswkFertigung
dc.titleInvestigation of Electromagnetic Pulse Welding for the Automated Production of Resource-Efficient Multi-Material Jointsen
dc.typeText
dc.type.publicationtypeConferencePaper
dcterms.accessRightsopen access
eldorado.secondarypublicationfalse

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