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High Velocity Tube Expansion for Making Axisymmetric Joints

Engineering & Physical Sciences
Materials
Industrial & Manufacturing
Nanomaterials
Transportation & Automotive
Welding
College
College of Engineering (COE)
Researchers
Vivek, Anupam
Daehn, Glenn
Johnson, Jason
Taber, Geoffrey
Licensing Manager
Smith, Richard smith.12123@osu.edu

TS-014774 — Making axisymmetric joints using pressure created by gas evolution from electrically vaporizing thin wires.

Current state-of-the-art technology for joining by tube expansion is hydroforming or electromagnetic forming (EMF). Hydroforming requires large presses, and EMF is limited to larger diameter products and electrically conductive driving materials. Generally, application of EMF is limited at high en…

The Need

Current state-of-the-art technology for joining by tube expansion is hydroforming or electromagnetic forming (EMF). Hydroforming requires large presses, and EMF is limited to larger diameter products and electrically conductive driving materials. Generally, application of EMF is limited at high energies and large numbers of operations by the availability of long-lived electromagnetic coils. There is a defined need for a low-cost, elegant solution for reliable tube expansion.

    The Technology

    Researchers at The Ohio State University, led by Dr. Anupam Vivek, have developed a method for high velocity tube expansion to make axisymmetric joints that overcomes large press and diameter limitations. The method uses an elastomer rod and a thin aluminum wire to create rapid expansion. Unlike EMF, this technique does not require the flyer material to be highly conductive. The wire vaporizes with a large current, causing high pressure on the rod, which transfers to the metallic tube. This allows for the desired joints with the second material.

    Commercial Applications

    • Dissimilar metal welding
    • Welding equipment and consumables
    • Power generation

    Benefits/Advantages

    • Impact joining through gas evolution from electrically vaporizing thin wires
    • Axisymmetric joints between two dissimilar metals
    • Allows for small diameter formation
    • Low cost of consumable nonconductive driving tube