C.Weddeling, V. Walter, P. Haupt, A.E. Tekkaya, V. Schulze, K.A. Weidenmann:
In: Journal of Materials Processing Technology, Vol. 225, pp. 240 ? 261, DOI: 10.1016/j.jmatprotec.2015.06.009


Space frames and multi-material structures are innovative designs to reducethe weight of a vehicle. But both lightweight design concepts have complex demands on joining technologies with the result that conventional processes are often pushed to their technological limits. Joining by electromagnetic crimping provides an interesting alternative to connect such structures without penetration or external heating. During electromagnetic crimping, pulsed magnetic fields are used to form a profile made out of an electrically conductive material into form-fit elements, like grooves, of the other joining partner. Thereby, an interlock is generated, which enables a load transfer.However, existing joint design methodologies require either extensive experimental studies or numerical modeling.To facilitate the connection design, an analytical approach for the prediction of the joining zone parameters with respect to the loads to be transferred is presented in this article. For the validation of the developed approach, experimental studies regarding the load transfer under quasi-static tension are performed. The major parameters considered in these investigations are the groove dimensions and its shape. In order to reduce the mass of a structure, hollow mandrels can be applied. To analyze how the reduced compressive strength of such inner connection elements influences the joining behavior and the load transfer of electromagnetically crimped connections, experimental studies are performed subsequent to the studies on the general groove parameters. Based on the obtained results, design strategies and a process window for the manufacturing of such joints are developed. To show the potential of electromagnetic form‑fit joining, example connections joined in accordance with the established design guidelines are tested under quasi‑static and cyclic loading.