Electromagnetic Joining of Aluminium Tube on Three Different Metal Cores Using Double Solenoid Coil

Abstract

Electromagnetic joining is a high energy rate and high-speed forming process. In this work, the aluminium tube was crimped over the aluminium, copper, and brass core by using the pulse discharge energy of the capacitor bank. A unique type of double solenoidal coil is used to carry out the research work on electromagnetic crimping. The compression-shear test was used to test the strength of the joints. The increase in the discharge energy also increases the joining strength. The maximum compressive strength when the discharge energy was 6.2 kJ was found to be 5.82, 5.51, and 4.5 MPa with aluminium, brass, and copper core, respectively. To study the distribution of the tube on the metal core microstructure at the interface was also analyzed, and it was found that the gap was 0-12 µm along the circumference for the 6.2 kJ discharge energy. The hardness at the interface was studied, and it was found that because of the impact of the tube with high velocity on the base core, the hardness value gets increased near the interface. Numerical simulations were also carried out to observe the deformation pattern and the maximum impact velocity. In the numerical study, the magnitude of the magnetic field and the Lorentz force was studied. © 2024 selection and editorial matter Ramesh Kumar, Arbind Prasad and Ashwani Kumar

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