An innovative integrated I-shape multi-layer coil was designed for the electromagnetic welding (EMW) process using the finite element method (FEM) combined with response surface methodology (RSM) to minimize the required discharge energy of welding. The parameters of number of layers (n), thickness of layers (t), and distance between layers (d) have been varied to optimize the values of current peak (I), frequency (f), magnetic flux density (B), Lorentz force (F), and impact velocity (V), simultaneously. Investigation of parameters for the design of the coil was accomplished in Maxwell®16 and LS-Dyna®4 softwares. The output results of these softwares were optimized by response surface methodology (RSM) and desirability function (DF) in Minitab®17 software. It was observed that the discharge energy for welding the aluminum (Al) to stainless steel (SS) was decreased from 6.75 to 3 kJ. The optimized coil was verified experimentally to allow good-quality welding.

使用有限元方法（FEM）和响应表面方法（RSM）相结合的电磁焊接（EMW）工艺，设计了一种创新的集成式I形多层线圈，以最大程度地减少焊接所需的放电能量。改变了层数（n），层厚度（t）和层间距离（d）的参数，以优化电流峰值（I），频率（f），磁通密度（B）的值，洛伦兹力（F）和冲击速度（V）， 同时。在Maxwell®16和LS-Dyna®4软件中完成了线圈设计参数的研究。这些软件的输出结果通过Minitab®17软件中的响应面方法（RSM）和合意功能（DF）进行了优化。观察到，用于将铝（Al）焊接到不锈钢（SS）的放电能量从6.75降低到3 kJ。经过优化的线圈已通过实验验证，可以进行高质量的焊接。