Numerical Simulation and Experimental Study for Magnetic Pulse Welding Process on AA6061-T6 and Cu101 Sheet

Magnetic Pulse Welding (MPW) is a collision welding process, similar to Explosive/impact Welding (EXW), but it utilizes electromagnetic force as the acceleration mechanism. Therefore, the available energy is much lower than EXW and it makes the process safer and more reproducible for sheet seam welding. However, the available energy must be better focused and controlled. In the sheet seam MPW process, a flyer sheet is driven and collides with a target sheet. True metallic bonding is achieved at the mating interface if contact takes place above a critical impact velocity at an appropriate impact angle. The impact velocity and angle are determined by the primary and induced electromagnetic fields. Both of them are strongly related to the geometry of the electromagnetic actuator and the discharge characteristics. An MPW launch system that will robustly provide bonding can either be developed empirically or through simulation. Here we attempt to provide the basis for a simulation-based approach to system design. The oblique MPW impact of AA606-T61 and Cu101 were analyzed using the newly available LS-DYNA®. Electromagnetism (EM) module in This module allows performing coupled mechanical/thermal/electromagnetic simulations. The simulation can predict the impact velocities and the temperature distribution along the mating interface. The simulation results were validated with measurement by Photon Doppler Velocimetry (PDV) measurement. Additionally, the simulation results also indicated rapid thermal cycling on the mating interface.