基于双线圈双驱动的弱导电性难变形金属电磁脉冲焊接运动行为与焊接性能

doi:10.19595/j.cnki.1000-6753.tces.250537

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Abstract Electromagnetic pulse welding (EMPW) achieves metallurgical bonding by utilizing electromagnetic forces induced in metal workpieces to drive their high-speed deformation and collision. However, for weakly conductive and difficultly deformed metals, such as zirconium alloy and stainless-steel, the use of a single driver has been proved to be inadequate for achieving bonding. Therefore, a novel EMPW method based on dual-coil and dual-drive was proposed, whose feasibility is validated through theoretical analysis, simulation, and experiment.
T2 copper plates were served as driver plates, while Zr-3 zirconium alloy plates and 304 stainless-steel plates were the workpieces to be welded. By analyzing the motion dynamics of the plates during both single-drive and dual-drive welding processes, as well as the relationship between driver plate thickness and skin depth, it was determined that the electromagnetic force induced in the driver plate must overcome not only its own deformation resistance but also that of the workpieces being welded.
A simulation model for zirconium alloy and stainless-steel plates EMPW was established in COMSOL software. In dual-drive EMPW, the zirconium alloy and stainless-steel plates exhibited negligible induced eddy currents due to the shielding effect of the copper drive board. The dual-drive welding method demonstrated a smaller magnetic flux density while achieving higher induced eddy current density and electromagnetic force density. The electromagnetic force generated during single-drive welding method was insufficient to induce a collision between the zirconium alloy and stainless-steel plates, resulting in inferior welding performance compared to dual-drive welding method.
An EMPW experimental platform for zirconium alloy and stainless-steel plates was established. Welding experiments were conducted using an asymmetrical dual H-typed coil. Welding experiments were conducted under a discharge voltage of 11, 12, 13 and 14 kV using both single-drive and dual-drive methods. Metallurgical bonding could not be achieved with the single-drive approach, whereas successful bonding was realized with the dual-drive method. The tensile test results showed that the tensile strength of the joint is higher than that of the zirconium alloy base material. Scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) analyses revealed distinct wavy patterns at the bonding interface, with elemental diffusion and mechanical interlocking identified as the primary bonding mechanism.
The following conclusions can be drawn from theory, simulation and experiments: (1) The specific situation for selecting the EMPW method based on dual-coil and dual-drive has been determined. The dual-drive welding method for weakly conductive and difficultly deformed metals can improve energy utilization efficiency. (2) Compared to single-drive welding, dual-drive welding exhibits a smaller magnetic flux density but achieves higher induced eddy current density and electromagnetic force density, enabling faster movement of the zirconium alloy and stainless-steel plates. (3) Under the conditions of this study, the primary bonding mechanism in dual-coil and dual-drive EMPW for zirconium alloy and stainless-steel plates is elemental diffusion and mechanical interlocking, and the joint tensile strength exceeds that of the base material itself.

Key words： Electromagnetic pulse welding (EMPW) weakly conductivity difficult deformation dual-coil dual-drive

Received: 04 April 2025

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TM89

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	Li Chengxiang
	Chen Dan
	Wu Zhaoxiao
	Shu Yihang
	Zhou Yan

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Li Chengxiang,Chen Dan,Wu Zhaoxiao等. Motion Behavior and Welding Performance of Weakly Conductive and Difficultly Deformed Metal Electromagnetic Pulse Welding Based on Dual-Coil and Dual-Drive[J]. Transactions of China Electrotechnical Society, 2026, 41(9): 2914-2925.

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https://dgjsxb.ces-transaction.com/EN/10.19595/j.cnki.1000-6753.tces.250537 OR https://dgjsxb.ces-transaction.com/EN/Y2026/V41/I9/2914

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