JOINING OF COPPER TO ALUMINIUM BY ELECTROMAGNETIC FIELDS JOIN EM

Transcription

1 JOINING OF COPPER TO ALUMINIUM BY ELECTROMAGNETIC FIELDS JOIN EM General Assembly of the Joining Sub-Platform Brussels, November 19 th, 2015 Verena Psyk

2 AGENDA Background of the JOIN EM project Principle of electromagnetic welding Advantages of electromagnetic welding Current obstacles hindering wide industrial implementation Aims and objectives of the project Technical approach Consortium 2

3 Background of the project Excellent electrical conductivity Electrical applications Excellent thermal conductivity Energy storage HVAC Electrical industry White goods High power electronics Important industrial Branches (selection) Copper 3 rd most frequently used material Chemical industry Electromobility Automotive & Transport Heating and cooling applications Very good chemical resistance 3

4 Copper-demand in Megatons Price in /lb Background of the project Electrical conductivity Thermal conductivity Copper (Source: Aluminium 58 MS/m 36 MS/m 401 W/mK 236 W/mK Density 8.9 g/cm³ 2.7 g/cm³ Price /ton* /ton* Jan 2000 Jul 2002 Copper Full copper solution Conducting/ dissipation zone Aluminium Jan 2005 Jul 2007 Feb 2010 Nov 2013 (Source: Heat / current lead-in zone Hybrid copper aluminium solution Aluminium section Remaining copper section (Source: ) 4

5 Price in /lb Major aims of JOIN EM Supplementing the heavy use of full copper components in applications related to electrical and thermal conductivity by high quality hybrid copper aluminium solutions Reduce material costs Reduce product weight Development of a flexible, highly productive, and cost effective joining process for high quality dissimilar material joints Enabling the industrial implementation of ElectroMagnetic Welding (EMW) Facilitating the exploitation of known process advantages in series production Jan 2000 Jul 2002 Copper Aluminium Full copper solution Conducting/ dissipation zone Jan 2005 Jul 2007 Feb 2010 Nov 2013 (Source: Heat / current lead-in zone Hybrid copper aluminium solution Aluminium section Remaining copper section 5

6 Pressure p(t) in MPa Inductor current I(t) in ka Process principle: electromagnetic compression of tubes Current Stromrichtungen directions Stoßstrom- Pulsed power anlage generator 120 I(t) L i Time t in µs R i C p ( t) 0 H a Hi Magnetic field lines Werkstück Workpiece Ausgangs- initial geometrie geometry final geometry Magnetic pressure p Werkzeugspule Inductor (direct (direktwirkend) acting) Time t in µs 6

7 Process principle: electromagnetic welding of tubes Current directions A Pulsed power generator I(t) Detail: A a L i v C V R i C Magnetic field lines Workpiece initial geometry final geometry Joining partner Magnetic pressure p Inductor (direct acting) 100µm 7

8 Coil current I(t) in ka Process principle: electromagnetic welding of sheets Workpiece (dynamic joining partner or flyer): Initial geometry Static joining partner Tool coil Time t in µs Detail: A v C V L i R i C Pulsed power generator 8

9 Coil current I(t) in ka Process principle: electromagnetic welding of sheets Workpiece (dynamic joining partner or flyer): Initial geometry Static joining partner Tool coil Current directions Time t in µs Detail: A v C V L i I(t) R i C Pulsed power generator 9

10 Coil current I(t) in ka Process principle: electromagnetic welding of sheets Workpiece (dynamic joining partner or flyer): Initial geometry Static joining partner Tool coil Current directions Time t in µs Detail: A v C V L i Magnetic field lines I(t) R i C Pulsed power generator 10

11 Coil current I(t) in ka Process principle: electromagnetic welding of sheets Magnetic pressure Workpiece (dynamic joining partner or flyer): Initial geometry 120 Static joining partner A Tool coil Current directions Time t in µs Detail: A v C V L i Magnetic field lines I(t) R i C Pulsed power generator 11

12 Significant advantages of EMW No heating of large component areas No thermal softening No heat distortion No critical intermetallic phases Parts can be handled safely Precise adjustment of forces; high reproducibility High joint strength Short process time high production rate Higher formability due to high strain rates for many materials Environmental and operator friendly process No heat, radiation, gas, or smoke Low energy consumption No lubricants required No additives or filler materials 12

13 Important obstacles hindering wide industrial implementation to be overcome by JOIN EM Lack of validated and practically applicable guidelines for joint design Lack of developed simulation tools required for process design Lack of validated methods for designing durable and efficient tools Lack of appropriate joint evaluation methods (especially non-destructive) Lack of validated industrial case studies validating the applicability of the process in an industrial environment evaluating process and equipment design strategies in an industrial setting. quantifying advantages of EMW via economic efficiency calculations and LCA 13

14 Scientific knowledge objectives Experimental and numerical process analysis Development of simulation strategies Macroscopic modelling acting loads, deformations, impacting conditions Numerical model of a tube joining process Current supply Fieldshaper Inductor Microscopic modelling joint development and properties Development of non-destructive testing Inner joining partner Outer joining partner Source: Fraunhofer Deep understanding of behaviour of tool materials Development of a lifetime prediction methodology for tools for EMW 14

15 Technological knowledge objectives Development of validated process and joint design concepts Guidelines for obtaining high-quality joints Design, realisation, and evaluation of industrial demonstrator parts Development of suitable joint preparation approaches Design, realisation, and evaluation of tools High power electronics passive cooling Battery Source: Calyos HVAC White goods Source: Refco Source: Whirlpool Transport / automotive components Source: Cegasa Source: Alke 15

16 Scanning distance Implementation knowledge objectives Optimisation of processes and tools regarding the industrial manufacturing process chain and environment Optimisation of inspection and testing methods guaranteeing transferable load, throughput rate, and robustness Evaluation of strategies for automated processes and quality control Weld inspection by Laser-UltraSound Runtime of Ultrasound waves Source: Recendt Economic process and product evaluation via life cycle cost analysis Technological process and product evaluation Source: Vertech 16

17 Dissemination objectives Publication of a project brochure, poster, and flyer Publication of a newsletter Creation and maintenance of a webpage Video publications via internet Peer reviewed scientific publications Conference presentations Organization of workshops Development of training material Preparation of standards for EMW 17

18 Technical approach: 5 phases of the project work Component re-design Economic use of copper Functional optimisation of the part Exploiting process-specific advantages of EMW Development of joining strategies Optimisation of tools Suitable process parameters Optimised joint preparation strategies Quantification of process potentials and limit Numerically assisted tool design and lifetime prediction Optimised materials and manufacturing strategies Development of joint characterisation methods Demonstration and Dissemination Destructive and non-destructive techniques Automated testing Industrial demonstrator parts Life cycle analysis Publication of results 18

19 Partners of the consortium 19

20 Acknowledgement This project has received funding from the European Union s Horizon 2020 research and innovation programme under grant agreement No JOIN EM. 20