Magnetic Pulse & Solid-State Welding
Magnetic Pulse Welding (MPW) Coil & Flyer Velocity Calculator
Precision solid-state welding calculator for EV battery busbars, air conditioning tube-to-plug joints, and aerospace dissimilar metal joining. Calculate flyer radial velocity (v_p), magnetic pressure, and field shaper vector geometry.
1. Input Parameters
Capacitor bank energy: 5 - 32 kJ.
Radial clearance between tube and core plug: 1.0 - 2.5 mm.
Wall thickness: 0.8 - 2.0 mm.
Axial compression zone length: 15 - 40 mm.
2. Calculation Results
Radial Flyer Velocity (v_p)
385 m/s
Peak Magnetic Pressure
480 MPa
Dynamic Collision Angle (β)
14.2°
Jetting Jet-Flow Status
OPTIMAL JETTING
3. Dynamic Schematic & Tooling Guide
Magnetic Pulse Welding (MPW) Design Criteria:
- Surface Jetting Phenomenon: Solid-state atomic bonding requires a high-velocity metal jet (250 - 500 m/s) that strips the surface oxide layer immediately ahead of the moving collision point.
- Impact Angle Window: Dynamic collision angle β must fall strictly between 8° and 20°. Angles below 5° cause trapped air voids; angles above 25° cause excessive turbulence and weld tearing.
- Field Shaper Slot Vector: The single-turn field shaper must have a precision tangential cut-slot (W = 0.5 - 1.0 mm) with dielectric insulation to channel eddy currents into the target weld band.