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JOINing of copper to aluminium by ElectroMagnetic fields

Deliverables

Measurement set-up for process analysis of EMW

The measurement set-ups will be installed at the institutes having EMF equipment available (i.e. FRAUNHOFER, BWI, and INNOVALTECH). A short documentation of the setup will be provided describing the setup, the working principle and exemplary measurement results proving the functionality.

Realisation of the joined parts

Joined parts will be available at FRAUNHOFER, BWI, and INNOVALTECH. Exemplary results of the joint tests will be included in the reports provided in D2.3 to D2.14. This will also serve as proof for having achieved D2.2.

Report on standardisation

D7.1 is a report on the current state of the standards related to the industrial implementation of the JOIN’EM technology/process

Report on testing of tools for EMW

D4.4 will be subdivided into two major parts: the first one serves as documentation of the results of the lifetime investigations carried out on specific specimens in order to get more general information about the material. The second one documents the results of the functionality and durability tests performed on the complete tool. Thereby, the functionality is proved on the basis of exemplary (successful) joining results. The durability tests include documentation about the tool loading in relation to observed changes as cracking, deformations, or flashovers.

Report on the benchmarking study: developed demonstrator with connections of sheet metal parts for cooling and heating applications compared to the state-of-the-art products

D6.6 documents the performance of the demonstrator with connections of sheet metal parts for cooling and heating applications. This concerns especially the results of specific tests usually performed in production. This performance is compared to the performance of the state of the art solution in order to clearly document advantages and disadvantages of the innovation.

Synthesis report regarding the corrosion analysis

D5.2 summarises the description and the most important results of the corrosion analysis. Corrosion testing by salt spray testing and immersion testing will be contained as well as a comparison of mechanical joint properties after being exposed to a corrosive environment.

Report on the life cycle assessment

D7.4 gives a detailed description of the Life-Cycle-Analysis of the demonstrators produced with help of EMW. It will describe the environmental impacts obtained by EMW compared to conventional (i.e. thermal) joining, due to the absence of heat, radiation, gas or smoke, low energy consumption, and the absence of lubricants, additives or filler materials, etc. For a quantitative evaluation of the LCA especially the data determined for the state of the art solution in WP1 is relevant. It will serve as a direct comparison.

Report on the benchmarking study: developed demonstrator with connections of sheet metal parts for electrical applications compared to the state-of-the-art products

D6.7 documents the performance of the demonstrator with connections of tubular parts for electrical applications. This concerns especially the results of specific tests usually performed in production. This performance is compared to the performance of the state of the art solution in order to clearly document advantages and disadvantages of the innovation.

Report on the benchmarking study: developed demonstrator with connections of tubular parts for cooling and heating applications compared to the state-of-the-art products

D6.5 documents the performance of the demonstrator with connections of tubular parts for cooling and heating applications. This concerns especially the results of specific tests usually performed in production. This performance is compared to the performance of the state of the art solution in order to clearly document advantages and disadvantages of the innovation.

Report with specifications of the joint characterisation methods for the defined joint types

D5.1 summarises the results of the evaluation of different testing methods for characterising joints produced by EMW. Destructive as well as non-destructive testing methods will be considered and advice regarding the most appropriate testing methods to quantify the joint performance will be contained.

Report on numerical lifetime prediction method for EMW equipment

A description of the modelling approach used for numerical lifetime prediction in the project is given in form of a report. Thereby, specific aspects to be taken into account when modelling the durability of tools for EMW processes are described.

Report on technological feasibility of EMW for all suggested material combinations

Within D2.5 it the possibilities of joining by EMW will be proved for all material combinations chosen for investigation within this project. A list with suitable parameters and conditions for achieving a satisfying joining result will be provided.

Standardisation recommendation document

A document with standardisation recommendations, based on the results of the JOIN’EM project, to be disseminated through the Joining Standardisation National Contact points and CEN.

Training, workshops, and seminars

For organising and carrying out a number of training/dissemination workshops, a set of materials, like training manuals and guidelines will be developed and prepared. A database of videos and photos will also be created, with the assistance of all partners, to facilitate training. Documentation of workshops carried out will be done via submitting the agenda and the list of participants.

Project specific website

Design and creation of a project website presenting the importance and the benefits of the conversion to the new processes based on a number of examples and case studies. This website will act as an information repository regarding the developments, for the public, but also for EC members. It will be linked to social websites (LinkedIn, YouTube), allowing users to participate in the main discussions regarding the project results, while rising the interest in the project’s outcomes.

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Publications

Microscopic modelling of weld formation in EMW: Open questions

Author(s): K. Macocco, C. Scheffler, A. Deldicque
Published in: CSMA 2017 13ème Colloque National en Calcul des Structures, Issue every 2 years, 2017, Page(s) 8

Thermo-mechanical simulation of a magnetic pulse welding process with first experimental validations

Author(s): Deldicque, Amaury; Ghorbel, I.
Published in: 23ème Congrès Français de Mécanique, 2017

Manufacturing of hybrid aluminum copper joints by electromagnetic pulse welding – Identification of quantitative process windows

Author(s): Verena Psyk, Christian Scheffler, Maik Linnemann, Dirk Landgrebe
Published in: AIP Conference Proceedings volume 1892, 2017, Page(s) 110001
DOI: 10.1063/1.5008128

Electromagnetic Pulse Welded Aluminium to Copper Sheet Joints: Morphological and Mechanical Characterization

Author(s): K. Faes, I. Kwee
Published in: 7th International Conference on High Speed Forming, April 27th-28th 2016, Dortmund, Germany, 2016, Page(s) 299-308

Prozessanalyse für das Magnetimpulsschweißen von Aluminium-Kupfer-Mischverbindungen

Author(s): Verena Psyk, Christian Scheffler, Maik Linnemann, Dirk Landgrebe
Published in: 23. Sächsische Fachtagung Umformtechnik - Den Eigenschaften Form Geben, 2016, Page(s) 174-183

Prediction of linear and non-linear behavior of 3D woven composite using mesoscopic voxel models reconstructed from X-ray micro-tomography

Author(s): Yang Liu, Ilya Straumit, Dmytro Vasiukov, Stepan V. Lomov, Stéphane Panier
Published in: Composite Structures, Issue 179, 2017, Page(s) 568-579, ISSN 0263-8223
DOI: 10.1016/j.compstruct.2017.07.066

Process analysis for magnetic pulse welding of similar and dissimilar material sheet metal joints

Author(s): Verena Psyk, Christian Scheffler, Maik Linnemann, Dirk Landgrebe
Published in: Procedia Engineering, Issue 207, 2017, Page(s) 353-358, ISSN 1877-7058
DOI: 10.1016/j.proeng.2017.10.787

Incremental magnetic pulse welding of dissimilar sheet metals

Author(s): Verena Psyk, Maik Linnemann, Christian Scheffler, Petr Kurka, Dirk Landgrebe
Published in: MATEC Web of Conferences, Issue 190, 2018, Page(s) 02004, ISSN 2261-236X
DOI: 10.1051/matecconf/201819002004

Effect of the Welding Parameters on the Structural and Mechanical Properties of Aluminium and Copper Sheet Joints by Electromagnetic Pulse Welding

Author(s): Irene Kwee, Verena Psyk, Koen Faes
Published in: World Journal of Engineering and Technology, 2016, Page(s) 538-561, ISSN 2331-4249
DOI: 10.4236/wjet.2016.44053

Influence of process parameters on the weld quality of dissimilar Cu-Al magnetic pulse welded sheets

Author(s): Wim Demonie, Koen Faes, Wim De Waele
Published in: International Journal Sustainable Construction & Design, 2016, ISSN 2032-7471

Interfacial Morphology and Mechanical Properties of Aluminium to Copper Sheet Joints by Electromagnetic Pulse Welding

Author(s): I. Kwee, K. Faes
Published in: Key Engineering Materials, 2016, Page(s) 109-114, ISSN 1662-9795
DOI: 10.4028/www.scientific.net/KEM.710.109

Investigation of the weldability of copper to steel tubes using the electromagnetic welding process

Author(s): Simoen B., Faes K., De Waele W.
Published in: International Journal Sustainable Construction & Design, 2017, ISSN 2032-7471

Experimental investigation of the weldability of tubular dissimilar materials using the electromagnetic welding process

Author(s): Roeygens L., Faes K., De Waele W.
Published in: International Journal Sustainable Construction & Design, 2017, ISSN 2032-7471

Elektromagnetisch pulslassen van koper-staal buisverbindingen

Author(s): door Irene Kwee en Koen Faes
Published in: LASTECHNIEK, 2017, ISSN 0023-8694

Magnetimpulsschweißen erleichtert die Herstellung von Mischverbindungen

Author(s): Verena Psyk, Maik Linnemann und Christian Scheffler / Peter Königsreuther
Published in: Maschinenmarkt, 2016, Page(s) 62-65, ISSN 2199-2657