Electromagnetic Forming Washington DC

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Electromagnetic forming (EMF or Magneforming) is a type of high energy rate metal forming process that uses pulsed power techniques to create ultrastrong pulsed magnetic fields to rapidly reshape metal parts. The technique is sometimes called high velocity forming.

A rapidly changing magnetic field induces a circulating electrical current within a nearby conductor through electromagnetic induction. The induced current creates a corresponding magnetic field around the conductor. Because of Lenz's Law, the magnetic fields created within the conductor and work coil strongly repel each other.

In practice the metal workpiece to be fabricated is placed in proximity to a heavily constructed coil of wire called the work coil. A huge pulse of current is forced through the work coil by rapidly discharging a high voltage capacitor bank using an ignitron or a spark gap as a switch. This creates a rapidly oscillating, ultrastrong electromagnetic field around the work coil.

The high work coil current, typically tens or hundreds of thousands of amperes, creates ultrastrong magnetic forces that easily overcome the yield strength of the metal workpiece, causing permanent deformation. The metal forming process occurs extremely quickly, typically tens of microseconds and, because of the large forces, portions of the workpiece undergo high acceleration.

The forming process is most often used to shrink or expand cylindrical tubing, but it can also form sheet metal by repelling the workpiece onto a shaped die at a high velocity. Since the forming operation involves high acceleration and deceleration, mass of the workpiece plays a critical role during the forming process. The process works best with good electrical conductors such as copper or aluminum, but it can be adapted to work with poorer conductors such as steel.

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