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Magnetic pulse weldingforming of lightweight

casings for connecting the cable to plug connectorsE.L. Strizhakov

a, S.V. Neskoromny

a& S.O. Ageev

a

aDonsk State Technical University, Rostov-on-Don, Ukraine

Published online: 09 Apr 2015.

To cite this article:E.L. Strizhakov, S.V. Neskoromny & S.O. Ageev (2015) Magnetic pulse weldingforming oflightweight casings for connecting the cable to plug connectors, Welding International, 29:12, 988-990, DOI:

10.1080/09507116.2015.1012387

To link to this article: http://dx.doi.org/10.1080/09507116.2015.1012387

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Magnetic pulse weldingforming of lightweight casings for connecting the cable to

plug connectors

E.L. Strizhakov, S.V. Neskoromny and S.O. Ageev

Donsk State Technical University, Rostov-on-Don, Ukraine

It is proposed to produce lightweight screening casings from aluminium foil with a thickness of 0.15 0.2 mm using thecombined technological process of magnetic pulse weldingforming (MPWF) and thermal and force effects. The physicalprinciple of the currently available process is described and the welding conditions are presented. The zone of the lap-welded joint is studied by metallographic techniques. The application of a rig (dialectic matrix) is described and the generalshape of the tool with the rig for MPWF is shown. The standard connection of the casing in the connector and a newstamped-welded structure are compared. The new structure has better parameters and explosion safety, 100% protectionagainst interference and static electricity.

Keywords: magnetic pulse welding; forming; magnetic pressure; lightened housing

The development of advanced electronic technology, used

in space systems, has resulted in a reduction of current

consumption. The current has become comparable with

electrical interference and this has been accompanied by a

large increase in the requirements of the developers of

systems on the accuracy of transfer of signals and the

minimum losses and distortions. To protect against high-

frequency radiation, it is necessary to screen all elements

of the cables from interference.

The developers of the board systems have created new,

considerably lighter compound parts of the cables. Practical

steps have been made to introduce the new technology for

connection sections of the cables. In particular, the newconnection section of the cable with the lightweight all-

metal shell casing has been designed. The lightweight

screeningcasing of the connection of the cable in the plug is

the typical tubular component with a complicated shape.

To produce lightweight structures of tubular com-

ponents, experiments were carried out to develop and apply

the technology of producing stamped-welded casings from

aluminium foil with a thickness of 0.15 0.2 mm by the

method of magnetic pulsed treatment of the materials [1].

The sketch of the screening casing-connector is shown

inFigure 1.

The structure of the housing contains a cylindrical

threaded part, a conical section with stiffeners and a

cylindrical section with a smaller diameter for connecting

with the screening braid of the cable. The lap joint is

produced along the generating line by magnetic pulsed

welding (MPW).

In the process of magnetic pulse treatment, as in any

method of electric resistance welding, the component is

subjected to the thermal and force effects resulting from the

passage of electric current pulses through the working tool

induction coil. However, in this case, the thin wall tubular

components cannot be produced by traditional MPW by the

method with subsequent collision under an angle[1].

The authors of[2] proposed a combined technologicalprocess of magnetic pulsed welding forming (MPWF).

Welding is carried out with induced current passing through

the overlapping area of the edges of the component. The

magnetic pressure is used as the welding and forming

pressure. The principal diagram of MPWF is shown in

Figure 2.

The combined process may be described as follows:

after cutting the thin sheet component 1 is rolled up with a

overlap D and placed in the die having the shape of the

future component. The working tool induction coil 3

is positioned in the treatment zone.

The discharge of the generator of pulse current

produces a high frequency (5 100 kHz) electromagnetic

field in the induction coil 3 and under the effect of the

field the self-induction EMF is generated in the

component 1 rolled up with the overlap D. The inducedcurrent pulseIppasses through the component 1 and Joule

heat is generated in the overlap zone. The force, formed

under the effect of the induced current Ip with the

magnetic field of the induction coil 3, shapes the

component in the direction of the die [2]. A layer of

molten metal is ejected from the weld zone (overlap)

together with the adsorbed and oxide films and other

contaminants. The heated clean surfaces are compressed

together, the edges are pressed to the die and electric

resistance welding takes place [2].

Magnetic pressure Pm acts on the entire surface of the

component and carries out shaping of the component in

accordance with the configuration of the die. Consequently,

the process of electric resistance welding and forming of the

closed structures of complicated shape produced from the

sheetmaterialtakes place in a singledischarge of thegenerator

of pulsed currents with a duration of 50200ms. The

component is produced in a single system with a single pulse.

The technology of production of the stamped-welded

casing of the collector is reduced to the following

operations: elastic magnetic pulsed stamping com-

ponents 2, placing the component and the induction coil

to the shaped die, MPWF (the main process), inspection of

the quality of the stamped-welded component.

The quality of welding tubular components isevaluated visually by mechanical tests and thermal

cycling. The weight of the connector section is 10 times

lower in comparison with the standard structure.

q 2015 Taylor & Francis

Welding International, 2015

Vol. 29, No. 12, 988990,http://dx.doi.org/10.1080/09507116.2015.1012387

Selected fromSvarochnoe Proizvodstvo 2014 67 (12) 4850

http://dx.doi.org/10.1080/09507116.2015.1012387http://dx.doi.org/10.1080/09507116.2015.1012387

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The parameters of the welding conditions for different

structures of the casing with the diameter d 1050mm

change in the following ranges: stored energy W

100 500 J; the working discharge frequency of current

fd 20 50 kHz; working voltageU 13kV.

Metallographic studies of the weld zone did not show

the formation of common grains. Analysis of the

microstructure shows that the weld zone is typical of

solid-phase welding using the standard pulsed methods.

There is a sharp interface the bonding zone, similar to

explosive and classic MPW.1 Figure 3 shows the weld

zone in the aluminium foil.

Calculations of the required working frequency of

treatment show that to carry out MPWF without the

magnetic cushion[2,3], it is necessary to use a pulse current

generator producing the working frequency of the discharge

current of the order of 200 300 kHz. It is not possible toconstruct industrial equipment with these parameters on the

basis of standard components (condensers) and, therefore,

welding is carried out using dielectric dies.

The equipment is produced from glass textolite

ensuring the required durability (more than 1000 cycles)

at the given welding (magnetic) pressure.

The working frequency in welding multi-turn induc-

tion coils does not exceed 50 kHz [4], resulting in the

penetration of part of the magnetic flux into the gap

between the component and the die and also into the

equipment. However, the component is not subjected to

any counter pressure because of the formation of the

magnetic cushion. Part of the discharge energy is

unavoidably lost and the efficiency of the process is

reduced but the quality of treatment is not affected.

The experimental specimen of the new structure of the

cable connector is shown in Figure 4.

The new cable connector for the plug has better

properties as regards fire and explosion safety, 100%

protection against interference and static electricity. Theseproperties are essential for producing the reliable cable

network, especially in the case of components with

cryogenic parts.

Figure 1. Sketch of the screening stamped-welded casing of the connector.

Figure 2. Principal diagram of the combined process of MPWF: (1) the component; (2) the die; (3) the induction coil; D overlapping,PCG pulsed current generator; Tr step-up transformer; R rectifier; C condensers; D discharger; I p discharge current; H magnetic flux; Ii induced current; Pm magnetic pressure; Pf forming pressure; Pw welding pressure.

Welding International 989

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These studies were carried out at the Donsk State

Technical University in accordance with the Programme

of Applied Scientific Studies (project) of the Ministry of

Education and Science of the Russian Federation:

Investigation of the process and development of the

technology of magnetic-pulsed welding-forming of light-

weight casings of the board cables of components for

transport and space technology (agreement No.

14.574.21.0049, 19.6.2014).

References1. Glushchenkov VA, et al., Technology of magnetic-pulsed

treatment of materials. Samara: Fedorov Publishing House;2014.

2. Strizhakov EL, et al. Classification of methods andexamination of resistance magnetic-pulse welding. Svar.Proiz. 2003;8:1114.

3. Strizhakov EL, et al. Hypothesis for the formation of the jointand methods of selection and calculation of the weldingconditions and equipment for magnetic pulsed welding of lapjoints. Izv. VUZ, Sev.-Kavk. Region, Tekh. Nauki, Specialissue; 2005:7274.

4. Plotnikov VV, et al. Experimental studies of the process ofresistance magnetic-pulsed welding. Izv. VUZ, Sev.-Kavk.Region, Tekh. Nauki. 2001;3:3841.

0.01 mm

56.247.1HV 55.3 52.2 58.0 71.1 56.5 56.5 54.1 57,1 51.2

Figure 3. The zone of the welded joint Al Al, 100.

Figure 4. Design of the connector of the cable with thelightweight screening casing.

E.L. Strizhakovet al.990