Interference-Fit Joining of Aluminium Tubes by Electromagnetic Forming

Interference-fit joining of tubes by electromagnetic forming is an innovative and environmental friendly technology that can successfully replace conventional joining technologies based on fasteners, structural adhesives, welding and brazing. The technology works at room temperature, allows joining dissimilar materials and offers potential to foster new applications in the assembly of lightweight tubular frame structures. As with all new technologies, there is a need to understand interference-fit joining of tubes by electromagnetic forming in terms of its major parameters with the aim of identifying their influence on the overall strength of the joints and establishing the useful range of process operating conditions. This article investigates the interference-fit joining of aluminum-alloy tubes (AA6082-O) with mandrels made from different metallic and polymeric materials (AA6082-O, AISI1045 and Erlaton 6SA). Results show that the strength of the joint and the associated failure mechanisms are directly related to process parameters and materials.