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Electromagnetic compression of tubular profiles with high electrical conductivity is an innovative joining process for lightweight structures. The components are joint using pulsed magnetic fields which apply radial pressures of up to 200 MPa to tubular work pieces causing a symmetric reduction of the diameter with typical strain rates of about 104 sec-1. Since there is no contact between the components to be joined and the joining machine, any damage of component’s surface can be avoided. Friction stir welding (FSW) is a relatively new solid state joining technique and has been extensively developed for aluminum, magnesium, copper and titanium alloys as well as steels. The primal advantages of the process in comparison to conventional fusion welding are better mechanical properties, low residual stresses and distortion, and reduced occurrence of defects. In the present article, the influence of process and material parameters on the joint’s characteristics, material’s microstructure and the mechanical properties of electromagnetic compressed joints and friction stir welds using reinforced aluminum profiles is analyzed. The strength of the joint is determined by tensile tests. Finally, possible improvements of both techniques are outlined.

Influence of Process Parameters on Structure and Mechanical Properties of Joints Produced by Electromagnetic Forming and Friction Stir Welding