Welding is a fabrication process that’s used to join two or more workpieces. It’s typically performed using a device, known as a welder, that heats the respective workpieces, thereby fusing them together at the surface. Magnetic pulse welding, however, uses a different mechanism to join workpieces. Rather than heat, it uses magnetism. It’s a unique welding process that, when performed correctly, offers several unique benefits.
How Magnetic Pulse Welding Works
Originating in the 1970s, magnetic pulse welding is a solid-state welding process that leverages the properties of magnetism to join two or more workpieces. It involves the use of a specializing welding rig that produces short pulses of electromagnetism with the help of capacitors. The electromagnetic pulses generate a magnetic field that forces the workpieces to smash into each other at speeds in excess of 1,100 miles mph.
Benefits of Magnetic Pulse Welding
Since magnetic pulse welding uses electromagnetic pulses to join workpieces, it doesn’t create heat-affected zones. Most other welding processes, of course, create points of weaknesses in the areas of the workpieces where they are heated. Known as heat-affected zones, they are typically weaker and more brittle than other areas of the workpieces. Magnetic pulse welding doesn’t produce heat, though, so workpieces remain free of heat-affected zones.
Magnetic pulse welding is a corrosion-free welding process. Other types of welding processes leave behind impurities, including moisture, that can lead to corrosion. It may not occur immediately, but workpieces joined with other welding processes often suffer from corrosion. Thankfully, magnetic pulse welding doesn’t suffer from this problem. It’s a corrosion-free welding process that protects the joined workpieces.
There’s no need for filler materials with magnetic pulse welding. Normally, workpieces are welded using a filler material. As the workpieces heat up, they are joined with a filler material. Magnetic pulse welding, however, uses neither hear nor a filler material. Instead, it relies entirely on electromagnetism to join the workpieces.
Magnetic pulse welding works well for high-volume manufacturing applications. According to Wikipedia, it’s capable of performing up to 5 million welding projects per year.
It’s also working not that magnetic pulse welding is safe and non-toxic. Other welding processes may produce toxic gases as a byproduct, thereby requiring workers to wear respirators or other forms of protection. Magnetic pulse welding, however, doesn’t produce any gases or fumes. It’s a green welding process that’s safe for workers.