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Product designers are frequently constrained by the restrictions of traditional joining technologies which place limitations on the type of joint, the materials that can be joined and the quality of the process.
Pulsar's MP-Weld™ allows manufacturers to improve significantly their product designs and production results by enabling dissimilar metals to be welded together thus enabling the use of lighter and stronger material combinations. Pulsar's MP-Weld delivers better joining results and superior quality at a higher production rate and at less cost than any conventional joining process.
MP-Weld has been tested and machines are producing parts for leading manufacturers worldwide. MP-Weld has proven particularly suitable for the automotive and white goods industries, where reducing manufacturing and material costs, reducing weight as well as improving yield and quality, are major challenges. For the automotive industry, MP-Weld offers applications for welding climate control system components, fuel filters, earth connectors, drive shafts, engine support, body construction elements and cables. For the white goods industry, MP-Weld offers applications for welding aluminum and copper tubes as well as condenser battery outlets.
MP-Weld™ Principles
A high energy current is discharged through a coil surrounding the workpiece. This high and extremely fast current creates magnetic forces between the coil and the workpiece that accelerate the outer workpiece towards the inner one thereby generating a solid state cold weld. This electromagnetic pulse welding process is executed at a very high speed and takes just milliseconds.
MP-Weld™ Main Characteristics
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Fast - less than 100 µS
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Welds conventionally non-weldable materials, such as Al- 7075
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Welding shape: circular tubes, rectangular tubes or any other shape of a tube
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Welding experience of up to 120mm in circular tubes diameter and up to 350mm circumference with other shapes
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Wall thickness of outer tube: up to 5 mm
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Wall thickness of inner tube: at least 1 mm
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Weld joint is stronger than the weaker base metal
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No filler material or shielding gases required
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No corrosion development in the weld area
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Safe, "green" and clean process
Mechanical properties
MP-Weld is a cold process that avoids the creation of micro-cracks in the weld area. The material keeps its original strength and other mechanical properties. In addition, as no internal stress is created in the material during the welding process, no further stress release processes are required.
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Microscopic view of Al6061 weld |
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Aluminum to copper after MP-Weld - good weld results |
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Aluminum to copper after tight crimp - no weld |
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Comparison - MP-Weld vs. tight crimp |
Welded Materials
Pulsar has vast experience in welding a variety of combinations for different industrial applications. The table below displays some of the material combinations that we have welded successfully.
MP-Weld™ Advantages
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Enables Designs Previously Not Possible
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By welding dissimilar materials
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By welding non-weldable materials
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By allowing the use of lighter and stronger materials
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Cuts Manufacturing and Component Costs
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Production rate higher than any other conventional joining process
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Eliminates re-work: negligible process failures
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No need for pre or post weld deburring or cleaning
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Consumables: no filler wire or shield gases used
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Superior quality
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Cold process: no heat treatment degradation
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Higher strength, with lower weight
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No corrosion development at the welding area
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Better conductivity
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'Green' Process - No Heat, Radiation, Gases, Smoke or Sparks |
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MP-Weld systems are well suited to high volume production. A single system can easily weld one million parts a year in two shifts. The systems require low maintenance, and can weld different parts with a short setup time.
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