JOINEM Demonstration of the feasibility of Electromagnetic Welding - - PowerPoint PPT Presentation

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JOINEM Demonstration of the feasibility of Electromagnetic Welding - - PowerPoint PPT Presentation

Jan 11, 2024 38 likes •311 views

71st IIW Annual Assembly & International Conference Commission III-B Friction Based Processes JOINEM Demonstration of the feasibility of Electromagnetic Welding applied to dissimilar materials Andr Cereja 1 , Koen Faes 2 , Verena Psyk

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71st IIW Annual Assembly & International Conference Commission III-B Friction Based Processes

JOIN’EM – Demonstration of the feasibility of Electromagnetic Welding applied to dissimilar materials

André Cereja 1 , Koen Faes 2, Verena Psyk 3 , Christian Hofer 4

1 European Welding Federation

2 Belgian Welding Institute 3 Fraunhofer - Institute for MachineTools and FormingTechnology IWU 4Research Center for Non-Destructive Testing GmbH (RECENDT)

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Overview

  • Facts and Figures
  • Motivation and Expected Results
  • JOIN’EM Video
  • Electromagnetic Pulse Welding (EPW)
  • Analysis of the joining process
  • Development of joint characterisation methods
  • Development of multiscale simulation strategies
  • Tool development
  • Development of industrial demonstrators
  • JOIN’EM Results
  • Conclusions

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Facts and Figures

  • Project: JOINing of copper to aluminium by ElectroMagnetic fields (JOIN’EM)
  • Call: FoF-12-2015, Industrial Technologies for advanced joining and assembly

processes for multi-materials

  • Duration:

01.09.2015 - 31.08.2018

  • Budget:

4.7 M€

  • Coordinator:

Fraunhofer IWU

  • Website:

join-em.eu

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Motivation and Expected Results

  • Copper: 3rd most used material in the world
  • State
  • f

art: heavy use

  • f

full copper components to take the best advantage of the material’s high electric and thermal conductivity

  • Goal: multi-material hybrid aluminium-copper,

aluminium-steel and copper-steel parts: ▪ Reduction of costs ▪ Reduction of component’s weight

Copper Aluminium Electrical conductivity 58 MS/m 36 MS/m Thermal conductivity 401 W/mK 236 W/mK Density 8.9 g/cm³ 2.7 g/cm³ Price ~4,478 €/ton ~1,550 €/ton

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Electromagnetic Pulse Welding (EPW)

  • Solid-state welding process
  • Joining ≠ material combinations

Aluminium Steel Copper

JOIN’EM Results

  • Analysis of the joining process
  • Development of joint characterisation methods
  • Development of multiscale simulation strategies
  • Tool development
  • Development of industrial demonstrators

Motivation and Expected Results

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JOIN’EM Video

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Electromagnetic Pulse Welding (EPW)

Process characteristics Similar or dissimilar materials Joint formed without heat No harmful fumes nor slag No temperature induced problems

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Tubular Sheet metal Material combination: aluminium - copper

Electromagnetic Pulse Welding (EPW)

Joint Configuration

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Influencing parameters

  • Capacitor charging energy
  • Geometrical parameters

Quality parameters

  • Joint strength
  • Leak tightness
  • Electrical conductivity
  • Micrographicinvestigation

Collision parameters

  • Impactvelocity
  • Impactangle

Identification of Process windows

JOIN’EM Results

Analysis of the joining process

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Material combination: copper-steel Tubular Specimen

JOIN’EM Results

Analysis of the joining process

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JOIN’EM Results

Analysis of the joining process Interfacial morphology

Deformation

Tubular Specimen

Waviness on the interface

Material combination: copper-steel

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Interfacial morphology: aluminium-steel

JOIN’EM Results

Analysis of the joining process

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Interfacial morphology: copper-brass

JOIN’EM Results

Analysis of the joining process

Copper-brass

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Interfacial morphology: copper-aluminium & copper-steel

JOIN’EM Results

Analysis of the joining process

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Destructive

Micrographic investigation Corrosion test Lap shear test Compression test Peel test Hardness test

Non-destructive

Electrical resistance measurement Visual examination Laser ultrasound test Leak test

JOIN’EM Results

Development of joint characterisation methods

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JOIN’EM Results

Development of joint characterisation methods

Destructive

F F Lap shear test

F F

F Peel test Corrosion test F Compression test

F

SEM – element mapping

Micrographic investigation

Light microscopic study

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JOIN’EM Results

Development of joint characterisation methods

Non-destructive

Leak testing U V U R= I I Electrical resistance measurement Visual examination Laser ultrasound test

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Material combination: copper-steel

Leak testing

Stand-off distance:

  • 1.0mm
  • 1.5mm
  • 2.0mm

Small stand off distance → lower impact velocity → worst weld quality Thicker tube → higher strength and thickness → Less plastic deformation

Tubular Specimen

JOIN’EM Results

Development of joint characterisation methods

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Laser Ultrasound Testing - sheet

JOIN’EM Results

Development of joint characterisation methods

good connection no connection

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Laser Ultrasound Testing - tube

JOIN’EM Results

Development of joint characterisation methods

Backwall Echo

GOOD SAMPLES: PULSE ECHO FROM the backwall combined with low echos caused by the interface

Specimen JE-CS-R2.4

Copper-steel tube without leakage

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JOIN’EM Results

Development of multiscale simulation strategies

Macroscale

Coupled electromagnetic and structual mechanical simulation

Microscale

Mixed smoothed particle hydrodynamics and Lagrange model

Flyer T arget Coil

  • Exp. verification

T

  • ol durability

Workpiece deformation

3D stress distribution Interface pressure

Fatigue analysis

Collision parameters

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JOIN’EM Results

Development of multiscale simulation strategies

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Investigation of tool materials

  • Conductor materials
  • Insulation / housing materials

Design and manufacturing and investigation of tool systems

  • Tube applications
  • Sheet metal applications

Durability testing of tool systems

  • Testing of materials and components
  • Testing of full tool systems

Tube welding coils

Multi-turn coil including fieldshaper Single-turn coil

Sheet welding coils

Trident-shaped coil winding U-shaped coil winding Openable coil

JOIN’EM Results

Tool development

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Three industrial demonstrators

  • Tube connections for heating and cooling applications
  • Sheet metal connections for heating and cooling applications
  • Sheet metal connections for electrical applications

Full demonstrators also serve for studying industrial implementation issues

  • Concept development for automation and control
  • Economic efficiency calculation
  • Life cycle analysis

JOIN’EM Results

Development of industrial demonstrators

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Passive cooling of high power electronics White goods Automotive components Battery

JOIN’EM Results

Development of industrial demonstrators

HVAC

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Conclusions

The EU-funded JOIN’EM project had a focus on improving the state of art of a solid state joining process: electromagnetic pulse welding; Research institutes and industrial partners developed a number of results to assure that the academic results could successfully be transposed to industrial applications; The project focused on multi-material combinations: aluminium-copper, aluminium-steel and copper-steel; Two joint configurations were evaluated: tube and sheet; JOIN’EM characterized the electromagnetic pulse welding process, including relevant process windows, simulation algorithms for workpiece deformation and tool durability, and destructive and non-destructive testing methods; Process validation was performed with a number of industrially relevant demonstrators.

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This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 677660.