MAGNETIC PULSE

WELDING
By
GAUTHAM SARANG

INTRODUCTION
Magnetic pulse

welding(MPW) is a solid
statewelding processthat
usesmagneticforces
toweldtwo workpieces together.
Theweldingmechanism is most
similar to that of
explosionwelding.

Cold Welding/Solid State Welding

Process
Similar To Explosive Welding (EXW) .
The Underlying Principles Of EXW
And MPW Are The Same.
Mpw Is More Clean And Precise
Driving Force : Electromagnetic Force
high-speed impact welding

Working Principle
tremendous amount of energy is

compressed and discharged in an

extremely short period of time.
The work pieces are placed
inside a coil.
systems can discharge up to
than 2 millions amps in only 100
microseconds

The high energy flows in the coil, and

the discharge of electric energy

induces "eddy currents" in the
external work piece
Both currents induce magnetic fields,
which oppose each other.
The reaction forces forcing the
external part towards the internal part
at high velocity to cause welding.
The impacting speed is more than
1000 km/h.

This

results
in
a
permanent
distortion, without spring-back of the
workpiece.

The actual process lasts no longer

then 100 microseconds.

No protecting atmosphere, filler
materials or other aiding materials
are necessary
The material does not get warmer
than 30C.
No heat affected zone
Metal is not degraded

Bonding area of different dissmilar joints

MPW PARAMETERS
Discharge Energy
Stored energy in the capacitor bank

is discharged into the coil

this energy is responsible for the
movement of the flyer metal.
Discharge within few microseconds
Increasing voltage or capacitance,
increases the discharge energy

the shearing strength of the welds

will be enhanced
Threshold value of the discharge
energy to produce the weld
minimum and maximum energy to
the weld perfectly without tearing full
joining

Standoff Distance
distance between parts prior to the

discharge.
The space is to gain velocity and
acquire kinetic energy that is going to
be transformed into impact energy.
optimum value of standoff distance,
which varies according to the welding
materials.

Magnetic Pressure
Magnetic pressure is driving the flyer

metal into the parent metal

Due to induced Eddy Current, the
magnetic pressure will oppose the
magnetic field from the coil
magnetic pressure must be optimum
(high) for successful bond
High magnetic pressure obtained
with high discharge energy or high
frequency current.

Impact velocity
Influenced by the energy and the standoff

distance.
High impact velocity causing plastic
deformation at the interface between parts to
weld.
High velocity jet will remove any
contaminants or oxidation particles from both
contact surfaces
Velocity is directly correlated with the energy
and discharge time
At low velocity, the flyer work piece will
collapse and no bonding is produced.

What MPW Can Weld

Aluminum to aluminum.

Aluminum to copper.
Aluminum to magnesium.
Aluminum to titanium.

Copper to copper.

Copper to steel.

Copper to brass.

Nickel to titanium.

Nickel to nickel.

Steel to steel.

ADVANTAGES
The weld is stronger than the parent

material
A protecting atmosphere, filler
materials or other aid materials are
not necessary
no heat affected zone is created, and
no loss of material properties takes
place.
the welded workpieces can be
unclamped immediately after welding

It is an ecological welding process, since

no heat, radiation, gas or welding fumes

are produced.
Allows designs previously not possible
High repeatability
Reliable and well suited to high-volume
production (MTBF typically 1-5 million
welds)
Many welding combinations using
dissimilar metals are possible
Green process (no heat, no sparks, no
smoke, no radiation)
High quality, very aesthetic and cleaner

High precision (single micron

precision obtainable by adjustment of

magnetic field)
No distortion
No corrosion development in the
welding area
All these advantages translate into
significantly lower costs and much
higher quality and productivity
Clean process (no pre- or post-weld
cleaning)

LIMITATIONS
MPW is limited to tubular geometries

and lap joints.

it is not possible to create a butt weld
with MPW.

APPLICATIONS
Dissimilar metal joints

Aluminium to copper

Aluminium-Stainless

steel (c) : Pulsar Ltd

Parts from the automotive industry

MPW vsMIG/MAG welding (airconditioning

parts)

Fuel filters

Drive axis (aluminium - steel

connection) and pressure vessel in an
airconditioning system

THANKS