Wave formation mechanism in magnetic pulse welding

Wavy interface morphology is observed in Magnetic Pulse Welding (MPW) similarly to that of the Explosion Welding process (EXW). It is recognized that interfacial waves are formed in a periodic manner and have well defined wavelength and amplitude. The phenomenon of wave formation in EXW has been subjected to extensive investigations in which empirical and numerical models have been published. In the present study, a wave formation mechanism for MPW is presented. This wave-creation mechanism was studied by evaluating the influence of sample geometry on wave morphology using stereoscopic optical microscopy. It was found that interfacial waves are formed in a Kelvin–Helmholtz instability mechanism. Reflected shock waves interact with the welding collision point at the weld interface, where interferences are the source for the wave's initiation. The collision energy, impact angle, and the geometry of the joint, were found to have the most significant influence on the waves' characteristics. An empirical relationship between interfacial wavelength and the free moving distance of the shock waves in the welded tubular parts was found.