Uniform Pressure Electromagnetic Actuator – An Innovative Tool for Magnetic Pulse Welding

The uniform pressure electromagnetic actuator (UPEA) is an innovative tool design for electromagnetic forming applications. In this article its suitability for magnetic pulse welding is demonstrated. To facilitate the process design, a simple mathematical model based on analytical equations describing the electromagnetic behavior of the system and the mechanical behavior of the workpieces under impulse loads is presented in this manuscript. The goal of the model is to predict the workpiece velocity considering the input energy, equipment and setup characteristics as well as mechanical properties of the workpiece. To validate the model, experimental analyses with aluminum-to-aluminum joints were conducted.