Magnetic Pulse Welding systems are well suited to high volume production. A single system can easily weld one million parts a year in two shifts. The systems require low maintenance and can weld different parts with a short setup time.
The conductive workpiece is placed inside or next to a coil which accelerates it over 1mm to impact the second workpiece at extremely high speed. The acceleration is a result of repelling magnetic fields between the workpiece and the coil, produced by the eddy current in the workpiece.
Magnetic pulse crimping is very similar to the magnetic pulse forming of cylindrical products, except that the inner part of the assembly replaces the die in the latter process. The process is suitable for cylindrical, elliptical, and rectangular workpieces.
Correctly designed joints made by the Magnetic Pulse Crimp process are typically stronger than the parent material. In this process, compression of the tube will normally result in a wall thickening, which adds to the joint strength. The main advantage compared to conventional crimping methods is smooth 360 degree crimp
Industries such as automotive and white goods manufacturers produces billions of sheet metal parts per year. A major challenge for these manufacturers is to reduce the cost associated with producing dies. Cost savings become even more significant for parts that require several processing steps and dies.
Magnetic Pulse Forming is a solution for forming and perforating processes reduce cost significantly. Magnetic Pulse Forming has ability to cut, form and perforate sheet metals or tubes into complicated shapes, in a single step with a single-sided die.
Hydroforming is based on the ultra-high-speed deformation of metal using shockwaves in water via the discharge of current from a Magnetic pulse system, an electric arc is generated in water between two electrodes. This electric arc vaporizes the surrounding water, converting electrical energy into an intense shockwave of mechanical energy.
The shockwave simultaneously transforms the metal workpiece into a visco-plastic state and accelerates it onto a die, enabling forming of complex shapes at high speeds in cold conditions all of which happens in a matter of milliseconds. The total cycle time including charging time of the system is in seconds.
This simulation shows the pinch of an aluminum steel tube onto a stainless steel rod in order to predict dynamic angles and velocities needed during a magnetic pulse weld.
The one-turn coil induced a current in the composite tube and a magnetic field in the gap. Together, they generate Lorentz forces that accelerate the tube on its axis.