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| Inverted Trapezoidal Cross-Section H-Shaped Coil for Electromagnetic Pulse Welding |
| Xiong Qi1,2, Ma Chaojie1,2, Yan Nuo1,2, Chen Kaichuang1,2, Wang Yizhe1,2 |
1. Hubei Provincial Engineering Research Center of Intelligent Energy Technology China Three Gorges University Yichang 443002 China;
2. College of Electrical Engineering & New Energy China Three Gorges University Yichang 443002 China |
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Abstract Electromagnetic pulse welding technology combines the advantages of high-speed forming and solid joining and is ideally suited for joining dissimilar metals. Welding coils are the key components of an EMPW system. H-shaped coils are widely used in plate welding due to their small size and easy assembly. However, most of the H-shaped coils used in existing studies have rectangular cross-sections, and the effect of different cross-section shapes on the weld quality of plate parts is rarely studied. This paper compares and analyses the Lorentz force generated by three types of coils with various cross-sections and explores the relationship between the geometrical parameters of the coil cross-section and the weld quality of plate parts.
Taking copper and aluminum plate parts as the research object, the two-dimensional electromagnetic pulse welding simulation model of circuit-magnetic field-structure field coupling is established using finite element software. The plate's dynamic deformation process is the same under the action of three kinds of cross-section coils. Before the plate collision, the movement velocity at the center of the plate is maximum. After the plate collision, the motion velocity at the edge of the collision area is maximum and decreases gradually to both sides. The Lorentz force exerted by the rectangular cross-section coil on the plate is the largest, the trapezoidal cross-section coil is the smallest, and the Lorentz force generated by the inverted trapezoidal cross-section coil is smaller than that of the rectangular cross-section coil. Based on the welding window theory, the maximum effective welding width of the inverted trapezoidal coil is 0.877 9 mm, the rectangular coil is 0.847 8 mm, and the trapezoidal coil is 0.333 6 mm. The effective welding width of the plate increases and then decreases with the rise of the upper bottom edge width of the inverted trapezoidal coil. The maximum effective weld width of the plate is 0.933 2 mm for the upper bottom edge width of 7 mm, which is 10.07% higher than that of the rectangular cross-section coil.
The study results show that (1) the inverted trapezoidal cross-section coil has the best welding performance. (2) As the width of the upper bottom edge of the inverted trapezoidal cross-section increases, the effective weld width of the plate increases and then decreases. An optimum parameter exists for the width of the upper bottom edge. (3) The magnitude of the collision velocity of the plate is not the only factor that determines the welding quality of the plate. Welding quality is also related to the contact area of the plate after collision.
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Received: 06 October 2024
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2025, Vol. 40 
