Magnetic Pulse Welding (MPW) is a green process as it eliminates the need of fillers or flux and do not produce dangerous fumes. It is a solid-state high velocity impact welding that uses electromagnetic forces to weld two work pieces together.

This technique uses a very short current pulse (~100 μs), which is obtained by fast current discharge from capacitor bank into a tool coil. This current produces high magnetic field inside the tool coil, which generates an eddy current in the work piece.

Repulsive electromagnetic forces are created on the surface of outer work piece which accelerates it to impact with other work pieces at higher velocities (>300 m/s). Dissimilar metal joints of Al-Cu, Ti-Cu, Ti-SS and Al-SS are obtained at 35 T magnetic fields generated inside the tool coil by the discharge current from 200 kJ capacitor bank.

The welded joint had qualified helium leak test and good wavy morphology is seen across the weld interface. Corrosion rate is measured at the interface of these dissimilar metal joints obtained by MPW. Bimetallic corrosion is observed at the contact area.

The weld is flawless and stronger than the base metal. The process is nearly instantaneous and very green.

This article is shared by Surender Kumar Sharma, Rohini Kumar Chebolu, Renu Rani, Shobhna Mishra, JMVVS Aravind, Rishu Kumar, G Kiran Kumar, Ramanaiah Nallu & Archana Sharma