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Process Of Joining Dissimilar Materials Using Magnetic Pulse Welding

Abstract: Disclosed is a process of joining Aluminium tube to mild steel rod by Magnetic Pulse Welding Process (MPW) by obtaining an optimized welding window. The process includes placing dissimilar-material components (202, 204) to be welded on a magnetic pulse welding setup; setting a stand-off distance at 1.20 mm to 1.5 mm; setting an operating voltage at 13 kV to 16.5 kV; and activating a coil (206), surrounding the dissimilar-material components (202, 204), of the magnetic pulse welding setup to join the dissimilar-material components. [FIG. 9]

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Notices, Deadlines & Correspondence

Patent Information

Application #
Filing Date
04 September 2019
Publication Number
10/2021
Publication Type
INA
Invention Field
MECHANICAL ENGINEERING
Status
Email
delhi@lsdavar.in
Parent Application
Patent Number
Legal Status
Grant Date
2024-02-13
Renewal Date

Applicants

TATA STEEL LIMITED
BISTUPUR,JAMSHEDPUR, JHARKHAND-831001, INDIA

Inventors

1. SUMAN PATRA
Tata Steel Ltd., Bistupur, Jamshedpur, Jharkhand-831001, India.
2. GURPREET SINGH
House No. 786 A, RAIL COACH FACTORY, KAPURTHALA- 144602, PUNJAB

Specification

Claims:I/We claim: 1. A process of joining dissimilar material components using magnetic pulse welding, the process comprising: placing dissimilar-material components (202, 204) to be welded on a magnetic pulse welding setup (200); setting a stand-off distance at 1.20 mm to 1.5 mm; setting an operating voltage at 13 kV to 16.5 kV; and activating a coil (206), surrounding the dissimilar-material components (202, 204), of the magnetic pulse welding setup (200) to join the dissimilar-material components. 2. The process as claimed in claim 1, wherein one component is an aluminum tube (204) and another component is a mild steel rod (202). 3. The process as claimed in claim 2, wherein the aluminum tube (204) is wrought Aluminium grade HE-15. 4. The process as claimed in claim 2, wherein the aluminum tube thickness is 1.2 mm to 1.4 mm. 5. The process as claimed in claim 1, wherein a discharge current applied on the coil (206) has a frequency of 14.9 kHz throughout the welding process. 6. The process as claimed in claim 1, wherein the stand-off distance is a radial gap between the inner side of one component with an exterior side of another component. 7. The process as claimed in claim 1, wherein the overlapping Length between the dissimilar material component is 0.5W± 1 (W being width of the coil). 8. The process as claimed in claim 2, wherein dia of aluminum tube is 33.9 mm 9. The process as claimed in claim 2, wherein dia of mild steel rod is 31.1 to 31.5 mm 10. A lap joined aluminium tube and mild steel rod as claimed in any of the claims 1-9 with weld percentage of 57.08 to 91.7 %. , Description:DESCRIPTION PROCESS OF JOINING DISSIMILAR MATERIALS USING MAGNETIC PULSE WELDING TECHNICAL FIELD [0001] The present disclosure relates generally to welding techniques. Particularly, but not exclusively, the disclosure relates to a process of joining dissimilar material components using magnetic pulse welding. BACKGROUND [0002] Background description includes information that may be useful in understanding the present subject matter. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed subject matter, or that any publication specifically or implicitly referenced is prior art. [0003] Magnetic Pulse Welding (MPW) process is similar to explosive welding where a flyer is accelerated towards a target metal with the help of magnetic force rather than an explosive force. Originally, MPW was developed for the nuclear industry, however, later this process has found its way into automotive and aerospace industries due to non-application of external physical binders. The absence of toxic fumes and radiation makes MPW an eco-friendly process compared to other conventional techniques. [0004] In MPW, one workpiece is accelerated towards other with very high velocity and the resulting impact results in the formation of solid-state welding. FIGS 1A and 1B show a schematic arrangement of a sample setup 100 during the magnetic pulse welding process. In setup 100, 160 µF capacitors C are charged to the desired level by alternating current supply and instantaneously discharged through a coil producing a high-intensity magnetic field by Ampere’s law. In accordance with Lenz’s law, eddy currents are produced on the surface of a flyer 102. Eddy currents having magnetic force opposite of coil field experiences the Lorentz’s force and the flyer 102 collides with a target metal 104. This high energy impact causes a severe plastic deformation resulting in a solid-state bonding between the two workpieces. The skin depth of the eddy currents produced on the flyer 102 is related to the permeability and conductivity of material of the flyer 102. The skin depth is denoted by (d) and can be written as: [0005] Here, d is skin depth in (m). is the conductivity of the material in (mO-1), µ the permeability of the workpiece in (Hm-1), and f is the frequency of the transient current in (Hz). Aizawa has given the magnetic pressure generated by the welding equation given below. [0006] Here P is the magnetic pressure in (Pa), B is the magnetic flux density in (T), t is the thickness of the plate in (mm). [0007] A prior art titled magnetic pulse welding aluminium tubes to steel bars by M. Kimchi form Edison Welding Institute, and H. Shao, W. Cheng, and P. Krishnaswamy from Engineering Mechanics Corporation of Columbus (USA) has been identified. The prior has employed a field shaper to concentrate the magnetic field which makes the entire set up costly. OBJECTS OF THE DISCLOSURE [0008] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed hereinbelow. [0009] In view with the challenges faces during joining Aluminium to Steel using conventional techniques, the foremost object of the present disclosure is to attain solid-state bonding between the two materials having significant joint strength. [0010] An objective of the present disclosure is to establish a process window of the material combination that can be used in the magnetic pulse technique. [0011] Yet another objective of the present disclosure is to provide a process for solid-state joining of dissimilar metals (such as Aluminium to mild steel sheet) while ensuring high joint strength, high mass production, and homogeneous bond characteristics. [0012] Yet another objective of the present disclosure is to provide an economical set up for solid-state joining of dissimilar metals (such as Aluminium to mild steel sheet). [0013] These and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated. SUMMARY [0014] This summary is provided to introduce concepts related to the process of joining dissimilar material components using magnetic pulse welding. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. [0015] The present disclosure relates to a process of joining Aluminium tube to mild steel rod by Magnetic Pulse Welding Process (MPW) by obtaining an optimized welding window. The process includes placing dissimilar-material components (202, 204) to be welded on a magnetic pulse welding setup; setting a stand-off distance at 1.20 mm to 1.5 mm; setting an operating voltage at 13 kV to 16.5 kV; and activating a coil (206), surrounding the dissimilar-material components (202, 204), of the magnetic pulse welding setup to join the dissimilar-material components. [0016] In an aspect, the aluminum tube is wrought Aluminium grade HE-15. [0017] In an aspect, the aluminum tube thickness is 1.2 mm to 1.4 mm. [0018] In an aspect, a discharge current applied on the coil (206) has a frequency of 14.9 kHz throughout the welding process. [0019] In an aspect, the stand-off distance is a radial gap between the inner side of one component with an exterior side of another component. [0020] In an aspect, the overlapping Length between the dissimilar material component is 0.5W± 1 (W being width of the coil). [0021] In an aspect, diameter of aluminum tube is 33.9 mm [0022] In an aspect, diameter of mild steel rod is 31.1 to 31.5 mm [0023] The present disclosure further relates to a lap joined aluminium tube and mild steel rod with weld percentage of 57.08 to 91.7 %. [0024] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components. [0025] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure. [0026] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS [0027] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which: [0028] FIGS 1A and 1B illustrate a schematic arrangement of a sample setup during the magnetic pulse welding process; [0029] FIG.2A-2C illustrate a schematic of a magnetic pulse welding (MPW) setup, in accordance with an embodiment of the present disclosure; [0030] FIG. 3 illustrates a schematic of the position of a flyer tube and a target metal rod inside a working coil of the MPW setup, accordance with an embodiment of the present disclosure; [0031] FIG. 4 illustrates an aluminum flyer tube and a steel target rod, after welding and the subsequent during peel test, in accordance with an embodiment of the present disclosure; [0032] FIG 5A illustrates the welding window of the aluminum flyer tube with thickness of 1.25 mm, in accordance with an embodiment of the present disclosure; [0033] FIG. 5B illustrates a graph showing a percentage weld variation at two different radial gaps for 1.2 mm aluminum flyer tube, in accordance with an embodiment of the present disclosure; [0034] FIG. 6 illustrates stereographic evidence of weld followed by alphabetic label which correlates to FIG. 5B illustrates a graph showing a percentage weld variation at two different radial gaps for 1.2 mm aluminum flyer tube, in accordance with an embodiment of the present disclosure; [0035] FIG. 7A illustrates a welded window for aluminum flyer tube with 1.4mm thickness, according to an embodiment of the present disclosure; [0036] FIG. 7B illustrates a percentage weld variation at two different radial gaps for 1.4 mm aluminum flyer tube, in accordance with an embodiment of the present disclosure; [0037] FIG. 8 illustrates a stereographic proof of a weld followed up by alphabetic order connecting it with the percentage weld proportion shown in FIG 7B, in accordance with an embodiment of the present disclosure; [0038] FIG. 9 illustrates a process of joining dissimilar material components using magnetic pulse welding, according to an embodiment of the present disclosure. [0039] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present subject matter. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in a computer-readable medium and executed by a computer or processor, whether or not such computer or processor is explicitly shown. DETAILED DESCRIPTION [0040] In the present document, the word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any embodiment or implementation of the present subject matter described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. [0041] While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the disclosure to the forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure. [0042] The terms “comprises”, “comprising”, “includes” or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, device or method that includes a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method. [0043] In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense. [0044] Hereinafter, a description of an embodiment with several components in communication with each other does not imply that all such components are required. On the contrary, a variety of optional components are described to illustrate the wide variety of possible embodiments of the present disclosure. [0045] FIG. 2A-2C illustrate a schematic of a magnetic pulse welding (MPW) set up 200, in accordance with an embodiment of the present disclosure. In the MPW setup 200, an arrangement of a target metal rod (mild steel) 202 and a flyer tube (aluminum) 204 are placed co-axially with a coil 206. As depicted in FIG. 1 earlier, capacitors of limit 160 µF are charged up to an operating voltage selected by an operator. Once the capacitors are fully charged, a high current switch is closed for sending a current through the coil 206. This current will induce a magnetic field in the coil 206. The changing magnetic field will induce eddy currents in the conductive outer workpiece, also named the flyer tube 204. Further, due to the shielding effect of an electrical conductor, the flyer tube 204 will prevent the magnetic field of passing through for creating a difference in magnetic field between the inside and the outside of the flyer tube 204. Therefore, considering the Lorentz force, the magnetic field outside the flyer tube 204 will exert a force on the flyer tube 204 due to the eddy currents for thrusting the flyer tube 204 inward in radial direction. If correctly executed, the high velocity of the inward motion and thus the high-energy impact between outer and inner workpieces (202, 204) will result in bonding. During the collision, the atoms of the adjacent surfaces are brought together for overcoming the repulsion force which drives them apart. The distance between the atoms is now small enough to enable sharing of electrons and the creation of an intermetallic phase for creating a bond. [0046] As shown in FIG. 2A, the portion of flyer tube 204 directly beneath the coil 106 is varied by adjusting the length X and the radial distance or standoff distance between them is changed by machining the diameter (D) of the target metal rod 202, as shown in FIG. 2C. FIG. 2B shows the dimensions of the flyer tube 204. [0047] FIG. 3 illustrates a schematic of the position of the flyer tube 204 and the target metal rod 202 inside the working coil 206. In the present disclosure, the total coil width and therefore the working length (LC) is 13 mm and the portion of the flyer tube 204 inside the coil 206 is depicted by LW. In an experiment, a first attempt was made with LC=LW resulting in poor discontinuous atomic bonding of the flyer tube 204 with the target metal rod 202. Then, strive was made with LW

Documents

Application Documents

# Name Date
1 201931035564-STATEMENT OF UNDERTAKING (FORM 3) [04-09-2019(online)].pdf 2019-09-04
2 201931035564-POWER OF AUTHORITY [04-09-2019(online)].pdf 2019-09-04
3 201931035564-FORM 1 [04-09-2019(online)].pdf 2019-09-04
4 201931035564-FIGURE OF ABSTRACT [04-09-2019(online)].jpg 2019-09-04
5 201931035564-DRAWINGS [04-09-2019(online)].pdf 2019-09-04
6 201931035564-DECLARATION OF INVENTORSHIP (FORM 5) [04-09-2019(online)].pdf 2019-09-04
7 201931035564-COMPLETE SPECIFICATION [04-09-2019(online)].pdf 2019-09-04
8 201931035564-FORM 18 [05-09-2019(online)].pdf 2019-09-05
9 201931035564-RELEVANT DOCUMENTS [07-10-2021(online)].pdf 2021-10-07
10 201931035564-Proof of Right [07-10-2021(online)].pdf 2021-10-07
11 201931035564-PETITION UNDER RULE 137 [07-10-2021(online)].pdf 2021-10-07
12 201931035564-OTHERS [07-10-2021(online)].pdf 2021-10-07
13 201931035564-FORM 3 [07-10-2021(online)].pdf 2021-10-07
14 201931035564-FER_SER_REPLY [07-10-2021(online)].pdf 2021-10-07
15 201931035564-ENDORSEMENT BY INVENTORS [07-10-2021(online)].pdf 2021-10-07
16 201931035564-DRAWING [07-10-2021(online)].pdf 2021-10-07
17 201931035564-CLAIMS [07-10-2021(online)].pdf 2021-10-07
18 201931035564-FER.pdf 2021-10-18
19 201931035564-RELEVANT DOCUMENTS [10-01-2023(online)].pdf 2023-01-10
20 201931035564-POA [10-01-2023(online)].pdf 2023-01-10
21 201931035564-FORM 13 [10-01-2023(online)].pdf 2023-01-10
22 201931035564-US(14)-HearingNotice-(HearingDate-30-01-2024).pdf 2024-01-05
23 201931035564-Correspondence to notify the Controller [24-01-2024(online)].pdf 2024-01-24
24 201931035564-FORM-8 [29-01-2024(online)].pdf 2024-01-29
25 201931035564-FORM-26 [31-01-2024(online)].pdf 2024-01-31
26 201931035564-Written submissions and relevant documents [06-02-2024(online)].pdf 2024-02-06
27 201931035564-PatentCertificate13-02-2024.pdf 2024-02-13
28 201931035564-IntimationOfGrant13-02-2024.pdf 2024-02-13
29 201931035564-FORM 4 [26-07-2024(online)].pdf 2024-07-26

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