A Novel Coil Structure for Metal Sheet Magnetic Pulse Welding
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Date
2025-08-26
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Abstract
Magnetic pulse welding (MPW) of metal sheets is an efficient and environment-friendly
room temperature solid-state welding technology. However, the process involves significant
energy dissipation. Limited by the current coil structure, high energy is required to achieve
metallurgical welding of metal sheets. To address this issue, novel coil principle and
structure has been proposed. The current is simultaneously concentrated into a section of
conductor by a unique circuit design, achieving current summation and amplification,
thereby enhancing energy efficiency. Numerical simulations were performed to explore the
effects of coil parameters on current density, Lorentz force, and flyer sheet motion, revealing
that the coil structure can amplify current by 1.5 to 5.3 times as coil turns increase from 2 to
7. The flyer sheet velocity exceeded the critical welding velocity. Experimental results show
successful welding of 1060 (1.0 mm) / DP450 (1.0 mm) at 6.05 kJ and 5754 (1.0 mm) /
DP600 (1.0 mm) at 9.8 kJ, with all interfaces displaying metallurgical characteristics. These
findings confirm the excellent welding capability of the novel coil at low energy, which
results from a significant current amplification effect. This reduces the stringent
requirements for magnetic pulse discharge equipment, thereby facilitating the further
industrial application of MPW technology.
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Keywords
Magnetic pulse welding, Molecular dynamics, Metal sheet, Novel coil structure
Subjects based on RSWK
Elektromagnetisches Pulsschweißen, Blech, Spulensystem, Numerisches Modell, Experiment