Electromagnetic Processing for Elaboration of Dissimilar Joints. Case Studies with Aluminum

Magnetic pulse welding (MPW) has potential applications where fusion welding is problematic, such as in dissimilar joints or where the very part integrity, as in electronic components, is likely to be threatened by hot environments. The paper describes some critical applications such as: joining of similar joints between Al wire to Al plate for electric and hybrid applications, dissimilar joints of Al to Cu for electrical conductors, Al to Steel for vehicles, Manganin to Copper for cryogenic applications and joining flexible printed circuit boards. The inductor design and the part set up for the aforementioned applications are critical for successful implementation of MPW. Generally, an air gap between the driver part and the opposite stationary part is required. This prerequisite becomes penalizing in mass production. To circumvent this, the authors have developed innovative solutions via localized humps in case of sheets. The paper proposes to discuss process highlights and characterization of the joints.

Keywords: Magnetic pulse welding; Applications; Air gap; Similar and dissimilar metal joints; Inductor