Abstract Welding dissimilar metal tubes attracts interest for a wide range of automotive, aeronautical, and plant engineering applications as well as other consumables. Hybrid driveshafts or structural elements can meet mechanical requirements at a reduced weight. However, joining materials with strongly different thermo-physical properties is a challenge for conventional fusion welding processes. In Magnetic Pulse Welding (MPW), the weld formation is based on the high-velocity collision between the joining partners, without additional heat input. This allows for the fabrication of sound “cold” welds. MPW of tubular parts is usually realized by the radial electromagnetic compression of the outer “flyer” part and the subsequent impact on the inner “parent” part. This impact represents a harsh loading for the parent, which therefore is usually designed as a thick-walled or solid part to avoid damage or unwanted deformations. To further increase the lightweight potential, the objective of the present manuscript is the comprehensive analysis of MPW with thin-walled parent parts. Experimental and analytical investigations are presented, which enable to reduce the parent thickness without affecting the joint strength. The approaches comprise the observation of the impact and deformation behavior by inline laser-based measurement technology as well as the development of adequate, re-usable mandrels to support the parent parts. The focus is on aluminum flyer parts, which are welded to steel and copper parent parts. Critical values for the parent wall thickness are deduced and recommendations for the process design of MPW with thin-walled tubes are given.

中文翻译：

---

通过磁脉冲焊接连接异种薄壁管

摘要 焊接异种金属管引起了广泛的汽车、航空和工厂工程应用以及其他消耗品的兴趣。混合动力传动轴或结构元件可以在减轻重量的情况下满足机械要求。然而，对于传统的熔焊工艺来说，具有强烈不同的热物理特性的接合材料是一个挑战。在磁脉冲焊接 (MPW) 中，焊缝的形成基于接合伙伴之间的高速碰撞，无需额外的热量输入。这允许制造良好的“冷”焊缝。管状零件的 MPW 通常是通过外部“飞轮”零件的径向电磁压缩以及随后对内部“母体”零件的冲击来实现的。这种影响对父母来说是一种沉重的负担，因此，它通常被设计为厚壁或实心部件，以避免损坏或不必要的变形。为了进一步增加轻量化的潜力，本手稿的目的是对具有薄壁母件的 MPW 进行综合分析。提出了实验和分析研究，这能够在不影响接头强度的情况下减少母体厚度。这些方法包括通过基于在线激光的测量技术观察冲击和变形行为，以及开发足够的、可重复使用的心轴来支撑母部件。重点是铝制传单零件，这些零件焊接到钢和铜母件上。推导出母体壁厚的临界值，并给出了对具有薄壁管的 MPW 工艺设计的建议。