Abstract：Electromagnetic pulse welding (EMPW) represents a significant application of electromagnetic forming in materials processing. This technique employs electromagnetic forces to induce high-speed deformation and collision between metals, resulting in metallurgical bonding. Unlike conventional welding methods, EMPW requires no external heat source and occurs over extremely short durations, minimizing temperature rise and eliminating heat-affected zones. These features help suppress or even prevent the formation of brittle intermetallic compounds, thereby improving the quality of the welded joints. In EMPW, welding quality is determined by the collision velocity and angle, both of which depend on the electromagnetic force field acting on the metals. This force arises from the interaction between eddy currents induced in the metal and the pulsed magnetic field generated by the coil. By adjusting electromagnetic parameters, it becomes possible to precisely control the magnitude and distribution of the force field, thereby enhancing collision conditions and joint quality. Current research on optimizing the electromagnetic force field in EMPW can be categorized into three approaches based on optimization strategy and workpiece type: pulse discharge equipment optimization, flat workpiece driver optimization, and tubular workpiece driver optimization. This review explores the underlying principles, key technologies, and representative applications of each approach and outlines the major challenges that remain in the optimization of electromagnetic force fields. The first approach is pulse discharge equipment to optimize the electromagnetic force field. Such systems typically comprise a charging power supply, energy storage capacitors, discharge switches, and their control units. Adjusting the component parameters of the discharge circuit modifies the amplitude and frequency of the pulsed current. While this method does not change the spatial distribution of the electromagnetic force field, it allows for control over the amplitude and temporal characteristics of the force acting on the workpiece, improving the welding outcome. The second approach is the plate workpiece driver optimized electromagnetic force field. Drivers, as core components in EMPW, directly influence the strength and distribution of the magnetic field, eddy currents, and resultant electromagnetic forces. Unlike pulse discharge systems that primarily affect the time distribution of forces, flat workpiece drivers improve spatial distribution by modifying coil geometry and parameters. Structural adjustments to the driver can significantly improve weld quality through enhanced control of the force field's distribution. The third approach is the optimization of the electromagnetic force field by the tubular workpiece driver. The actuators required for EMPW of tubular workpieces are more complex than those for plate workpieces and usually consist of a coil and a field shaper. The coil is used to provide the magnetic field, and the field shaper is used to concentrate the magnetic energy. After the coil generates the magnetic field, the field shaper uses the skin effect and cooperates with the special structure to concentrate the magnetic field energy, to change the magnetic field distribution in the welding area, and achieve the purpose of adjusting the magnetic field distribution, enhancing the local magnetic field and improving the distribution of electromagnetic force field. By reasonably designing the structure and parameters of the tubular workpiece driver, the temporal and spatial distribution of the electromagnetic force field can be effectively optimized, thus improving the welding effect. Finally, the review highlights the prospects of EMPW and identifies critical challenges that must be addressed to advance its industrial application. EMPW holds great promise in fields such as aerospace, new energy vehicle manufacturing, and energy equipment production. However, several obstacles remain, particularly in optimizing electromagnetic force fields. Key challenges include increasing output energy, maximizing peak current, and optimizing frequency to meet diverse industrial requirements; achieving more precise control of the electromagnetic force field; and overcoming the limitations of single-driver systems. To address these issues, three future directions are proposed: enhancing the energy capacity of pulse discharge equipment, developing novel driver designs, and exploring combinations of multiple drivers. These efforts are expected to further refine the electromagnetic force field and accelerate the industrialization of EMPW.
李成祥, 吴赵骁, 陈丹, 周言. 电磁脉冲焊接中电磁力场优化方式研究进展[J]. 电工技术学报, 2026, 41(7): 2163-2180.
Li Chengxiang, Wu Zhaoxiao, Chen Dan, Zhou Yan. Research Progress of Electromagnetic Force Field Optimization Methods in Electromagnetic Pulse Welding. Transactions of China Electrotechnical Society, 2026, 41(7): 2163-2180.
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