Coupled Electromagnetic–Structural Simulation of Magnetic Pulse Welding

The present study deals with the coupled magnetic–structural analysis of magnetic pulse welding (MPW) process applied on a tubular workpiece. The study investigates the various criteria required for a successful weld between the mating members through a finite element model. The transient electromagnetic field phenomenon is coupled sequentially with mechanical phenomenon. The coupling between the magnetic field and the electrical circuit is formulated in the electromagnetic part of the model, whereas in the structural part, the impact velocities, the effective plastic strain and the shear stress induced in the workpiece are found from the numerical simulations. A viscoplastic material model with rate-dependent material properties is considered in the structural part. The effect of varying process parameters: input voltage and air gap between the two mating members on weld quality are computed through numerical simulations. Based on the results of the numerical simulations, an optimal weldability window is suggested