Magnetic pulse welding of high-strength aluminum alloy with enhanced Lorentz force via novel hollow field shaper

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology Pub Date : 2025-03-27 DOI:10.1016/j.jmatprotec.2025.118829

Junjia Cui , Wanting You , Hao Sun , Guangyao Li , Peng Wang , Qing Wang , Chenling Zheng , Chong Wang , Hao Jiang

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引用次数: 0

Abstract

Magnetic pulse welding (MPW) has been widely applied to join metallic tubes in the automotive and aerospace fields. However, low energy utilization of the device limits the Lorentz force and the application to high-strength alloys. A novel hollow field shaper structure is proposed to expand the range of potentially applicable materials. Topology optimization was employed to trade off the efficiency and the strength of the device. The welding of 6061-T6 aluminum-alloy tube and 1020 steel tube was realized. The joint strength has increased threefold. The results showed that under the enhanced Lorentz force, the element was diffused into each other. The numerical study found that the Lorentz force from the novel design was enhanced by 56 %. The radial deformation in the free deformation experiment increased by 243.3 %, validating the improvement of the force. By creating an analytical model, it was analyzed that the increase in force was due to the decrease in current division on the sloping surface of the hollow field shaper. Besides, the efficiency increased by 66.7 % implying lower energy costs. Thus, the proposed structure was validated to expand the materials range of MPW.

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利用新型空心场成形器增强洛伦兹力的高强度铝合金磁脉冲焊接

磁脉冲焊接（MPW）已广泛应用于汽车和航空航天领域的金属管连接。然而，该装置的低能量利用率限制了洛伦兹力和高强度合金的应用。提出了一种新型的空心场成形器结构，以扩大潜在适用材料的范围。采用拓扑优化来权衡器件的效率和强度。实现了6061-T6铝合金管与1020钢管的焊接。接头强度增加了三倍。结果表明，在增强的洛伦兹力作用下，元件相互扩散。数值研究发现，新设计的洛伦兹力提高了56% %。在自由变形实验中，径向变形增加了243.3 %，验证了力的改善。通过建立解析模型，分析了力的增加是由于空心场成形器倾斜表面的电流划分减少所致。此外，效率提高了66.7 %，这意味着能源成本的降低。因此，所提出的结构扩展了MPW的材料范围。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Journal of Materials Processing Technology 工程技术-材料科学：综合

CiteScore

12.60

自引率

4.80%

发文量

403

审稿时长

29 days

期刊介绍： The Journal of Materials Processing Technology covers the processing techniques used in manufacturing components from metals and other materials. The journal aims to publish full research papers of original, significant and rigorous work and so to contribute to increased production efficiency and improved component performance. Areas of interest to the journal include: • Casting, forming and machining • Additive processing and joining technologies • The evolution of material properties under the specific conditions met in manufacturing processes • Surface engineering when it relates specifically to a manufacturing process • Design and behavior of equipment and tools.