To make existing vehicles more fuel-efficient and to meet the coming needs of alternatively powered vehicles, automobile original equipment manufacturers needed lighter components.
Therefore, improved efficiency could only be gained by using new, lighter-weight materials, such as aluminum, and new manufacturing processes that reduced the use (and therefore the weight) of steel in welding.
The challenge that the industry faced was how to join different metals together so that the assembled components had the desired stiffness, strength, and dimensional quality.
Current manufacturing technologies that provided multi-metallic joints, such as the use of fasteners or adhesives, require additional implementation expense, such as processes and special design features, and may not achieve acceptable levels of strength and dimensional quality.
Once Magnetic Pulse Welding has been installed into vehicles, these lighter parts would result in increased fuel efficiency of 8 to 10 percent.
Space frames, Wheel armatures, slip rings, Tubular seat components, starter pinions, diesel pump components crimping, bellows, Automotive Climate Control Elements, Temperature Control and Thermostat Assemblies, Steering Linkage, Shock Absorbers, Attaching reinforce bands on oil filter, Assembly Body Parts, Stainless Steel Exhaust and suspension components can be done through this process.
Conventional techniques are available with varying use of pins, rivets, bolts, adhesives, keyways, polygon matching shapes, shrink fits and press fits. However, these methods are not as economical as desired, particularly when applied to drive shafts of vehicles.
In order to reduce vehicular weight, obtain smooth operation and improve fuel economy, driveshaft components have been formed from lighter materials such as alloys of Aluminum.
While Aluminum alloys have been an acceptable material because of their strength and lighter weight, problems have been experienced using conventional welding techniques with such components.
Attachment processes are critical to performance in weight-reduction initiatives involving rotating assemblies, such as drive shafts.
Minimizing forcing functions related to both the shaft’s mass and dimensional quality necessitated a new assembly approach, especially when using large-diameter, thin-walled tubular components.
- Cooler tubes
- Hybrid tubes
- Bi-metallic tubes
- HVAC filters HVAC tubes and tube connections
- Heat-exchangers T-joints Engine cradles (e.g. welding hydroformed aluminum to carbon steel)
- Earth connectors carbon steel to produce hybrid assemblies)
- Suspension arms
- Suspension parts
- Spring shafts
- Steering wheel armatures
- HP hydraulic brake pipes
Advantages over conventional welding :
- Replacing Laser Welding, TIG / MIG or Crimping
- Improved Results By Magnetic Pulse Welding
- Higher Quality and Yield
- Smaller Dimensions
- Hermetic sealing
- Repeatable Process
- Normal industrial tolerance
One of the most difficult problems in welding is to weld dissimilar metals such as aluminum and steel together. Hybrid structures of aluminum alloy and steel are suggested for reducing the weight of automobiles to improve fuel efficiency and control air pollution.
Therefore, the joining of steel and aluminum alloy in different shapes is receiving attention.
However, steel and aluminum are not compatible metals as far as fusion welding is concerned. The reason for this is attributed to the large difference between their melting points (660°C for Al and 1497°C for steel), the nearly zero solid solubility of iron in aluminum.
The challenge most of the industries faced was how to join different metals together so that the assembled components had the desired stiffness, strength, and Dimensional quality.
Current technologies that provided multi-metallic joints, such as the use of fasteners or adhesives, require additional implementation expense, such as processes and special design features, and may not achieve. This technology is well suitable for dissimilar welding without using any extra material
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