Magnetic Pulse Forming With a Vaporizing Conductive Layer
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Solution Overview
Problem
Magnetic pulse forming and welding methods require high electrical energy, leading to excessive stress and potential damage to the coil, limiting their effectiveness and lifespan.
Innovation Solution
A method involving a thin conductive layer positioned between the part and the coil, which vaporizes to create a pressure wave and Lorentz forces, reducing the energy required for forming and welding while minimizing coil stress, using a conductive layer and optional insulating layer to manage current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high intensity current is used in magnetic pulse forming/welding, then the part can be effectively formed or welded, but the coil experiences high temperatures and stresses that can weaken it, shorten its life, or even lead to irreparable damage
Solution Approach 1:
A conductive layer is introduced as an intermediary between the coil and the part. This layer absorbs the high current intensity and converts it to a pressure wave through vaporization, while the magnetic field acts on the part directly. This mediator protects the coil from direct contact with high currents and thermal stresses, resolving the contradiction between effective forming/welding and coil durability
Solution Approach 2:
The patent replaces the direct electromagnetic interaction between coil and part with a two-stage process: first, electromagnetic energy creates a pressure wave in the conductive layer; second, this pressure wave mechanically impacts the part. This substitution allows the coil to operate at lower current intensities while achieving the same forming or welding effect, thereby extending coil lifespan
2Manufacturing precision
If very high intensity current is discharged in a very short time, then the magnetic field is intense enough to form or weld thick parts, but the electrical energy consumption is considerable
Solution Approach 1:
The conductive layer undergoes a phase transition from solid to vapor when exposed to the magnetic field. This phase change absorbs energy and converts it into a pressure wave that impacts the part. By utilizing this phase transition, the system achieves effective forming or welding of thick parts with lower overall energy consumption compared to direct high-intensity current discharge
Solution Approach 2:
The patent uses pulsed magnetic fields with specific frequency and duration to create periodic pressure waves in the conductive layer. This periodic action allows for controlled energy delivery, achieving effective forming or welding while minimizing total energy consumption compared to continuous high-intensity current
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces energy consumption, allows forming and welding of thicker parts with lower coil stress, and extends the coil's lifespan by using lower current intensities and reducing thermal and plastic deformation.
Implementation Method 1
The current generates a variable magnetic field between the coil and the part, and induces eddy currents in this part
Implementation Method 2
These eddy currents associated with the surrounding magnetic field develop forces in the part which generate a strong acceleration
Implementation Method 3
The current induced in the conductive layer will cause the heating of said conductive layer
Implementation Method 4
When the heating energy is greater than the sublimation energy of the conductive layer, said conductive layer vaporizes, creating a pressure wave
Implementation Method 5
Conventionally, a device for implementing such magnetic pulse forming/welding processes comprises one or more capacitors connected to a coil to create a brief and intense magnetic field. The capacitor or capacitors are used to store a large quantity of electrical energy
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for shaping a part (2) by means of magnetic pulse, characterized in that it includes the steps of: - positioning a thin conductive layer (40) on the part; - positioning the part between a coil (10) and a matrix, the conductive layer being arranged between the coil and the part; - generating, by means of the coil, an induced current, said induced current being configured: - to vaporize the conductive layer, generating a pressure wave in the direction of the part; and - in association with a magnetic field generated by said induction coil, to accelerate the part in the direction of the matrix (30), pressing said part against said matrix, resulting in the part being shaped. The invention also relates to a method for welding parts by means of magnetic pulse.