Analytical Model and Experimental Validation of Single Turn, Axi-symmetric Coil for Electromagnetic Forming and Welding

Lightweight structures and assemblies formed and welded electromagnetically are widely used in various industries such as automotive, aerospace and electronics. One of the key factors in magnetic pulsed welding which causes the occurrence of the weld in the contact zone is the impact velocity. Experimental tests show that a minimum impact velocity (∼ 250m/s) is required to achieve a successful welded component. While some Finite Element packages exist that are capable of modeling the process and estimating the velocity, there is a lack of simplified and accuracy analytical modeling tools. In this paper, the magnetic pressure applied to the workpiece and the workpiece velocity were predicted for a single turn axi-symmetric coil. If the impact velocity is sufficient, a magnetic pulsed weld could be created. Such an analytical model helps eliminate empirical investigations to achieve the necessary velocity to produce successful magnetic pulse welding joints.