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Electro-Magnetic Pulse Welding of Similar and Dissimilar Metals

Sachin D. Kore* Mechanical Engineering Department, IIT
Guwahati, Assam, India *e-mail: sdk@iitg.ac.in

Abstract
Electromagnetic welding is a solid state welding process used for welding similar and dissimilar metals. It
uses the Lorentz force which is induced by eddy current and magnetic field, both of which are generated
in the work piece by a transient current in a coil in the vicinity. Lorentz force can be used for
electromagnetic welding of similar, dissimilar and difficult to weld metal combinations like Al-Al, Cu-to-
Cu, Al-Steel, Al-Al-Li, Al-Mg, Cu-to-SS, etc. The jetting action due to the high velocity of impact removes
the oxide layer present on the metal surface and creates the defect free weld.

Keywords: Electromagnetic, Welding

1. Introduction :
Need of weight reduction in automobile parts has developed the need of welding similar, dissimilar and
difficult to weld metal combinations. It has given rise to the development and growth of new welding
techniques such as high velocity welding. Electromagnetic is a high velocity welding technique in which
the force is generated by discharge of capacitor bank to accelerate the work piece to high velocity. This
method was invented in 1950; it developed rapidly between late 1960s and the early 1970s. Welding of
similar and dissimilar metal combinations like Al, Mg and Steel are difficult due to entrapment of oxide
in the weld, wide difference in their melting temperatures and the formation of brittle inter-metallic at
the interface. Recent work by Aizawa et al [1] and Kore et al.[2] has established the feasibility of
electromagnetic welding of similar and dissimilar metal combinations. Kore et al [3-7] have also
reported welding of difficult to weld metals like Al, Al Steel, Al-Mg, Cu-Cu, Cu-SS and the effect of
process parameters on the strength and width of the EM weld. Kore et al [8] have also reported the
modeling of EM welding process.

2. Experimental procedure and equipments :
It is a technique for welding of metals by means of high strength transient magnetic field. This field is
produced when capacitive stored energy is switched into an inductor. Fig 1 shows the schematic of
electromagnetic welding equipment. The main components involved in electromagnetic welding are
high-energy storage capacitor (C), high voltage switch, work coil and the job piece. The machines of
electromagnetic welding are available in the capacities ranging from 2 to 160 kJ. The operating voltages
are normally held around 1-10 kV depending upon the dielectric strength of the insulator. The discharge
current is usually between 100 and 400 kA.


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Fig 1 Schematic of Electromagnetic Welding Equipment

Depending upon the application the coils can be expendable or permanent. Expendable coils are cheap
and useful for only experimental work and feasibility trials. Such coils can be used only once as the large
current flowing upon discharging the capacitors vaporizes them. Production machines require the use of
permanent coils capable of withstanding repeated application of high voltages. Three types of coils most
commonly used in electromagnetic welding are compression, expansion, and flat coils.

2.1 Compression coils :
Compression coils enclose a portion of the workpiece as shown in Fig. 2 [9]. They are used to collapse
the workpiece inwards in a radial direction. Coils are available in the helical or wafer type construction
and can be designed as specific shapes or as general-purpose coils for use with field shapers.

Fig. 2 Compression Coil [10]

2.2 Expansion coil :
Expansion coils are inserted within the tubular workpieces as shown in Fig. 3 and are used to expand the
workpiece outward in radial direction. Like compression coil they are built either with single or multi
turn helical winding as required by application.

Fig. 3 Expansion Coil [10]
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2.3 Flat Coils/ Pancake Coils :
Flat coil shown if Fig. 4 has a spiral shaped winding and can be placed either above or below a flat
workpiece. In larger sizes they have been made with two parallel spiral windings to provide greater
strength. Typically flat coils have dead area in the center in which no magnetic pressure is developed.
The size of this area depends on the individual coil design. Flat coils are used with a die to form, coin,
blank, or dimple the workpiece. Flat coils have also been used to correct the unwanted local
deformation in very large parts.

Fig. 4 Flat coil [10]
2.4 Field shapers :
Field shapers shown in Fig. 5 [11], are used to concentrate the pressure to a specific location on the
workpiece. They are also used to adapt large diameter compression coils to small diameter workpieces.
Field shapers are single turn coils. Usually made from beryllium copper or hardened aluminium those
are inserted between the work coil and the workpiece. They receive energy from the work coil and
transfer it to the workpiece by induction. The slot made in field shaper changes the direction of flow of
induced current in the field shaper keeping it in same direction as the current direction in the coil. It
ensures the induced current direction in the job piece is exactly apposite of the current in the coil. The
diameter of the field shaper can be varied to the required size. Thus by using different size field shapers
same size coil can be used for the job pieces of different diameters. However field shapers must be
electrically insulated from work coil and the workpiece.
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Fig. 5 Field Shaper [11]
3. Electromagnetic Welding :
Electromagnetic impact welding is a solid state welding technique. It has the advantages of solid state
and impact welding process. Due to the ease in controlling the magnetic field in axis symmetric
structures, this technique has been commercialized only for the tubes. Recently this technology has also
been established for flat sheets. During the electromagnetic welding of two sheets, the sheets are
placed within the coil. The intense electromagnetic fields between the coil and sheets create high
electromagnetic pressure between them. This electromagnetic pressure drives the two sheets towards
each other and causes a strong impact between them. The impact pressure is sufficient enough to expel
away the surface contaminants and bring two nascent sheets together to create a bonding over the
interface. While traditionally difficult to join, similar and dissimilar metal combinations are used in a
variety of applications in an effort to reduce manufacturing costs, enhance strength and reduce weight.
Such applications are primarily found in the automotive, aerospace and fluid industries. Electromagnetic
impact welding offers a cost effective and efficient means for welding Al to Mg, Al to steel, Al to Al, Al to
Al-Li and other difficult to weld metal combinations. Electromagnetic impact welding has many
similarities to explosive welding, such as impact angle, velocity of impact and wavy interface after
welding [12-16]. The standoff distance between the flyer and base components was experimentally
proven to be effective between one and three times flyer component thickness [12-16]. However,
because electromagnetic impact and explosive welding use different energy source to create impact,
they have different characteristics and applications. Explosive welding is mainly used for sheet welding.
Explosive welding theory was initially developed by Botros [17] and Cowan [18, 19] and studied the
welding conditions like angle of impact and velocity for each material combination. Fig. 6 shows weld
interface of Al to Al EM weld [6] showing weld and no-weld zones. Due to the high velocity of impact the
EM welds of Cu to Cu (Fig. 7), Al to Al (Fig. 8) and Al to Al-Li (Fig. 9) sheets shows wavy interface similar
to the one observed in well known process of explosive welding. Due to the low velocity of impact and
variation in impact pattern the EM impact weld of Al to Steel (Fig. 10) shows continuous weld without
any defect and wavy pattern.

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Fig. 6 EM weld of Al to Al sheets [10]

Fig. 7 Wavy interface of Cu to Cu EM weld [11]


Fig. 8 Wavy Pattern of EM welding of Al to Al sheets [10]




Fig. 9 Wavy interface of Al to Al-Li EM weld [8] Fig. 10 EM weld of Al to SS sheets [9]

Numerical modeling of EM welding [8] has shown the normal component of Lorentz force acting at the
centre (shown in Fig 10) is responsible for the no-weld zone in the EM weld. Kore et al [5, 6] have found
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that electromagnetic impact welds of Al to SS and Al to Al sheets exhibit maximum shear strength at an
optimum value of standoff distance. Fig. 11 shows variation in shear strength with the variation of
standoff distance. At lower and higher values of standoff distance the velocities acquired by the sheets
were not sufficient to create the stronger welds. Samples prepared at optimum value of standoff
distance, when tested for its shear strengths, failed outside the weld. EM welding can produce welds
stronger than the parent metal at optimum welding conditions [9, 10].


Fig 12 Lorentz forces acting on the sheets [8]

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Fig. 11 Effect of standoff distance on shear strength of EM weld [6]


Electromagnetic welding technique being solid state welding technique has many advantages over
fusion welding techniques. Reduced tooling cost, quick production lead time, easy for automation,
reduced inspection and rework for electromagnetic impact welding and little cleaning required before
and after operation of welding, all these factors contribute for the lower manufacturing cost.

Summary:
The paper has revealed the fact that electromagnetic welding technique is extensively studied and
widely accepted for the welding of axis - symmetric and sheet metal parts. Ease in uniform distribution
of magnetic field for the axis - symmetric geometry made this technology more suitable for tubes. In
case of flat geometry parts, the uniform magnetic field distribution is a challenging job. Due to the
potential application of electromagnetic welding of flat sheets in automobile and aerospace
components, many researchers have now concentrated their research in the field of electromagnetic
welding of flat sheets.

Electromagnetic impact welding is similar to explosive welding except the input energy. It can join
dissimilar and difficult to weld materials. It is found to be more suitable to tubular structures. The
feasibility and the detailed analysis of EM welding of sheets have recently been established. Standoff
distance has significant impact on the shear strength of the EM welds. Variation in impact angle and
impact velocity can be the topic of future study to get the defect free EM welds.

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