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<p>The welding technology for large-diameter dissimilar metal tubes is experiencing growing demand in the manufacturing of critical components for the new energy sector, including aluminum-steel drive shafts and wind turbine bearings. Magnetic pulse welding (MPW), a high-speed and solid-state joining technology, offers significant advantages for welding dissimilar metals. However, its application has been constrained by challenges such as limited processing scalability and the difficulty of improving welding quality, particularly for large-diameter tubes. This study addresses these limitations through innovations in MPW equipment and processes. At the equipment level, a magnetic actuator featuring fiber reinforcement and a multi-turn winding field shaper (FS) is developed, achieving a discharge energy of 30&#xa0;kJ and a magnetic field strength of up to 33&#xa0;T. At the process level, a novel welding process window is constructed using welding magnetic field strength (B) and welding gap-length ratio (GLR) as key parameters. Experimental results show that magnetic fields of at least 18&#xa0;T and 21&#xa0;T are required to achieve low-quality and high-quality welding of aluminum and steel, respectively. This new welding window overcomes the limitations of conventional ones, which rely on discharge voltage and gap dimensions, by enhancing universality and adaptability. Furthermore, a three-dimensional welding window incorporating velocity, impact angle, and welding quality is developed for AA6061 and 304SS alloys, offering a comprehensive understanding of the factors affecting local joint performance. By applying these advancements, high-quality welding of 6061 aluminum alloy tubes (110&#xa0;mm in diameter, 3&#xa0;mm in thickness) to 304 stainless steel tubes is achieved, marking the largest reported diameter for aluminum-steel MPW applications. This breakthrough significantly broadens the applicability of MPW technology to large-scale industrial applications and establishes a foundation for further advancements in dissimilar metal welding.</p>

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Magnetic pulse welding of large-diameter aluminum-steel dissimilar metal tubes: actuator design, welding process, and mechanism

  • 期刊论文

  • 发表日期：

    2025年6月22日

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  • Xiaoxiang Li,
  • Mengxian Li,
  • Xinyu Tang,
  • Haixiang Liu,
  • Mengyuan Gong,
  • Zhipeng Lai,
  • Quanliang Cao,
  • Liang Li

摘要

The welding technology for large-diameter dissimilar metal tubes is experiencing growing demand in the manufacturing of critical components for the new energy sector, including aluminum-steel drive shafts and wind turbine bearings. Magnetic pulse welding (MPW), a high-speed and solid-state joining technology, offers significant advantages for welding dissimilar metals. However, its application has been constrained by challenges such as limited processing scalability and the difficulty of improving welding quality, particularly for large-diameter tubes. This study addresses these limitations through innovations in MPW equipment and processes. At the equipment level, a magnetic actuator featuring fiber reinforcement and a multi-turn winding field shaper (FS) is developed, achieving a discharge energy of 30 kJ and a magnetic field strength of up to 33 T. At the process level, a novel welding process window is constructed using welding magnetic field strength (B) and welding gap-length ratio (GLR) as key parameters. Experimental results show that magnetic fields of at least 18 T and 21 T are required to achieve low-quality and high-quality welding of aluminum and steel, respectively. This new welding window overcomes the limitations of conventional ones, which rely on discharge voltage and gap dimensions, by enhancing universality and adaptability. Furthermore, a three-dimensional welding window incorporating velocity, impact angle, and welding quality is developed for AA6061 and 304SS alloys, offering a comprehensive understanding of the factors affecting local joint performance. By applying these advancements, high-quality welding of 6061 aluminum alloy tubes (110 mm in diameter, 3 mm in thickness) to 304 stainless steel tubes is achieved, marking the largest reported diameter for aluminum-steel MPW applications. This breakthrough significantly broadens the applicability of MPW technology to large-scale industrial applications and establishes a foundation for further advancements in dissimilar metal welding.