Simulation Study on Dual-Coil Electromagnetic Pulse Welding of Dissimilar Metal Thin-Walled Tubes
摘要
During the electromagnetic pulse welding (EMPW) process of tubes, the high-speed collision between outer tube and inner tube is easy to cause the shrinkage of inner tube, and it is difficult to form metallurgical bonding. In this work, a dual-coil EMPW method based on the synergies gained from compression coil and expansion coil was proposed, and a three-dimensional simulation model of EMPW process of aluminum alloy tube (outer tube) and stainless-steel tube (inner tube) with coupling the electrical-magnetic-mechanical was established. The distribution pattern of magnetic flux density, induced eddy current, Lorentz force and the movement process of tubes with the effect of dual-coil were analyzed. The results showed that the maximum induced eddy current densities of aluminum alloy and stainless-steel tubes were 7.54 × 1010 A/m3 and 3.31 × 1010 A/m3, respectively. The maximum Lorentz force densities of aluminum alloy and stainless-steel tubes were 8.31 × 1011 N/m3 and 6.59 × 1011 N/m3, respectively. Besides, the maximum collision velocity of the aluminum alloy tube was 772 m/s, while that of the stainless-steel tube was 166 m/s. As the collision velocity decreased and the collision angle increased, the collision velocity and angle match the welding window, indicating that the method is feasible.