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<p><i>Magnetic Pulse Welding</i> (MPW) is an innovative <i>solid-state welding</i> technology that uses <i>high-speed electromagnetic forces</i> to achieve defect-free joints without melting the base materials. This paper presents a comprehensive numerical investigation into MPW for industrial applications, focusing on plates and tubular components. By leveraging coupled <i>electromagnetic</i> and <i>mechanical</i> models developed in COMSOL MULTIPHYSICS, this research explores critical parameters affecting weld quality, such as <i>material properties</i>, <i>geometries</i>, <i>air gaps</i>, and <i>energy levels</i>. The simulations demonstrate that Al/Al plate welding achieves complete joint formation within <InlineEquation ID="IEq1"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="161_2025_1409_Article_IEq1.gif" Format="GIF" Height="16" Rendition="HTML" Resolution="72" Type="Linedraw" Width="37" /> </InlineMediaObject> <EquationSource Format="TEX">\(10 \mu s\)</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mn>10</mn> <mi>μ</mi> <mi>s</mi> </mrow> </math></EquationSource> </InlineEquation> at a discharge current density of <InlineEquation ID="IEq2"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="161_2025_1409_Article_IEq2.gif" Format="GIF" Height="20" Rendition="HTML" Resolution="72" Type="Linedraw" Width="113" /> </InlineMediaObject> <EquationSource Format="TEX">\(3.2 \times 10^{11} A/m^3\)</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mn>3.2</mn> <mo>×</mo> <msup> <mn>10</mn> <mn>11</mn> </msup> <mi>A</mi> <mo stretchy="false">/</mo> <msup> <mi>m</mi> <mn>3</mn> </msup> </mrow> </math></EquationSource> </InlineEquation>, while dissimilar joints such as Cu/Al and Ti/Al require up to <InlineEquation ID="IEq3"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="161_2025_1409_Article_IEq3.gif" Format="GIF" Height="16" Rendition="HTML" Resolution="72" Type="Linedraw" Width="50" /> </InlineMediaObject> <EquationSource Format="TEX">\(12.5 \mu s\)</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mn>12.5</mn> <mi>μ</mi> <mi>s</mi> </mrow> </math></EquationSource> </InlineEquation> and <InlineEquation ID="IEq4"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="161_2025_1409_Article_IEq4.gif" Format="GIF" Height="16" Rendition="HTML" Resolution="72" Type="Linedraw" Width="37" /> </InlineMediaObject> <EquationSource Format="TEX">\(47 \mu s\)</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mn>47</mn> <mi>μ</mi> <mi>s</mi> </mrow> </math></EquationSource> </InlineEquation> respectively. In tube welding scenarios, similar material combinations (Al/Al) showed successful bonding within <InlineEquation ID="IEq5"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="161_2025_1409_Article_IEq5.gif" Format="GIF" Height="16" Rendition="HTML" Resolution="72" Type="Linedraw" Width="37" /> </InlineMediaObject> <EquationSource Format="TEX">\(20 \mu s\)</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mn>20</mn> <mi>μ</mi> <mi>s</mi> </mrow> </math></EquationSource> </InlineEquation>, while dissimilar pairs (Mg/Al and Cu/Al) required significantly more time and higher energy input. Weldability maps and deformation analysis confirm that air gap and coil geometry substantially impact welding time and joint quality. These results underline MPW’s potential for cost-effective, high-speed, and sustainable manufacturing in aerospace and automotive sectors.</p>

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A numerical investigation and process optimization of magnetic pulse welding for similar and dissimilar materials

  • 期刊论文

  • 发表日期：

    2025年8月4日

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  • Ilhem Boutana

摘要

Magnetic Pulse Welding (MPW) is an innovative solid-state welding technology that uses high-speed electromagnetic forces to achieve defect-free joints without melting the base materials. This paper presents a comprehensive numerical investigation into MPW for industrial applications, focusing on plates and tubular components. By leveraging coupled electromagnetic and mechanical models developed in COMSOL MULTIPHYSICS, this research explores critical parameters affecting weld quality, such as material properties, geometries, air gaps, and energy levels. The simulations demonstrate that Al/Al plate welding achieves complete joint formation within \(10 \mu s\) 10 μ s at a discharge current density of \(3.2 \times 10^{11} A/m^3\) 3.2 × 10 11 A / m 3 , while dissimilar joints such as Cu/Al and Ti/Al require up to \(12.5 \mu s\) 12.5 μ s and \(47 \mu s\) 47 μ s respectively. In tube welding scenarios, similar material combinations (Al/Al) showed successful bonding within \(20 \mu s\) 20 μ s , while dissimilar pairs (Mg/Al and Cu/Al) required significantly more time and higher energy input. Weldability maps and deformation analysis confirm that air gap and coil geometry substantially impact welding time and joint quality. These results underline MPW’s potential for cost-effective, high-speed, and sustainable manufacturing in aerospace and automotive sectors.