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Magnetic pulse welding involves the joining of two metallic parts in a solid state by the use of a short and intense electromagnetic impulses and the resulting impact between the parts. The coalesced interface undergoes visco-plastic deformation at a high strain rate and exhibits a wavy shape at a microscopic scale. A practical estimation of the electromagnetic pressure, impact velocity and welded joint length as a function of the process conditions and the electromagnetic coil geometry is required but currently not available. Three novel analytical relations for the estimation of the electromagnetic pressure, impact velocity, and welded joint length for magnetic pulse welding of tubes and sheets, are presented. These relations were developed systematically, following a dimensional analysis, and validated for a wide range of conditions from independent literature. The comparison of the analytically computed results and the corresponding values reported in the literature has illustrated that the proposed analytical relations can be used for the estimation of the electromagnetic pressure and impact velocity for the magnetic pulse welding of tubes and sheets with a good level of confidence. The analytically calculated results for the welded joint length show a little discrepancy with the corresponding experimentally measured values. Further investigations and more experimentally measured results are required to arrive at a more comprehensive analytical relation for the prediction of welded joint length.

Analytical Estimation of Electromagnetic Pressure, Flyer Impact Velocity, and Welded Joint Length in Magnetic Pulse Welding