Design and Experiment Study on Separable Electromagneic Crimping Coil of Copper-aluminum Transition Joints

WEI Wei; BAI Xiaobin; CHANG Jiang; LU Zhijian; YANG Lanjun

doi:10.13296/j.1001-1609.hva.2026.04.016

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Design and Experiment Study on Separable Electromagneic Crimping Coil of Copper-aluminum Transition Joints

Research & Analysis | 更新时间：2026-04-08

- Design and Experiment Study on Separable Electromagneic Crimping Coil of Copper-aluminum Transition Joints
- High Voltage Apparatus Vol. 62, Issue 4, Pages: 143-151(2026)
- 作者机构：
  
  国网陕西省电力有限公司宝鸡供电公司，陕西宝鸡 721000
  西安交通大学电工材料电气绝缘国家重点实验室，西安 710049
- 作者简介：
- 基金信息：
- DOI：10.13296/j.1001-1609.hva.2026.04.016
  CLC：
- Received：11 October 2025，
  
  Revised：2026-01-10，
  
  Published：16 April 2026
- 稿件说明：
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WEI Wei, BAI Xiaobin, CHANG Jiang, et al. Design and Experiment Study on Separable Electromagneic Crimping Coil of Copper-aluminum Transition Joints[J]. High Voltage Apparatus, 2026, 62(4): 143-151.
DOI：

WEI Wei, BAI Xiaobin, CHANG Jiang, et al. Design and Experiment Study on Separable Electromagneic Crimping Coil of Copper-aluminum Transition Joints[J]. High Voltage Apparatus, 2026, 62(4): 143-151. DOI： 10.13296/j.1001-1609.hva.2026.04.016.

摘要

磁场线圈是电磁成形设备的关键组成部分，其结构及性能影响着电磁成形的效果。目前基础研究中所提到的可分离式线圈存在能量利用率低、寿命低的问题，因此，为了将电磁成形技术应用于铜铝过渡接头制作领域，需要研发高强度、高能量利用率的可分离式磁场线圈。文中设计了基于外置集磁器的可分离式线圈，并使用可分离线圈进行了铜铝接头压接实验研究。通过电磁场—结构场有限元仿真，研究了放电频率、线圈和集磁器结构等参数对成形效果和集磁器工作区磁感应强度的影响规律；铜铝接头压接实验研究结果表明：随着脉冲电容器组放电电压的提高，外管形变不均匀度降低；并且铜铝接头的接触电阻阻值及波动范围减小，抗拉力增大，放电电压高于14 kV时，铜铝接头强度高于铝绞线本体；对放电电压14 kV及以上的接头界面微观分析发现，随着碰撞速度的增大，波状界面波长及峰值增大；对Cu/Al焊接界面线扫发现长度为2 μm左右的元素互扩散，并未发生界面熔融现象。因此铜铝接头结合机理主要分为以下两方面：由于元素互扩散在界面处形成原子键合；由于高速率撞击产生强烈塑形变形从而形成冶金结合。

Abstract

The magnetic field coil is a critical part of electromagnetic forming equipment

and its structure and performance influence the effect of the electromagnetic forming process. The seprable coil proposed in the present foundation study has such issues as low energy utilization and short lifetime.Therefore

to enable the application of electromagnetic forming technology in the filed of copper-aluminum transition joints

it is necessary to develope separable magentic field coil with high strength and high enerergy utilization.In this paper

the separable coil based on external magnetic collector is designed and the separable coil is used to perform the copper-aluminum joint crimping experiment study. The influence of such parameters as discharge frequency

the coil and magnetic collector structure on the forming effect and magnetic induction intensity of the working area of the magnetic collector is studied through electromagnetic-structural finite element simulation. Results from copper-aluminum transition joints crimping experiments indicate that with the increase of discharge voltage of the pulse capacitor bank

the uneven deformation of the outer tube is decreased. Moreover

the contact resistance and fluctuation range of the copper-aluminum joints are decreased

the tensile strength is increased. When the discharge voltage is above 14 kV

the strength of the copper-aluminum joints is higher than that of the aluminum stranded wire. It is found from the microscopic analysis of cable joint interfaces with discharge voltage at 14 kV and above that with an increase in collision velocity

the wavelength and peak of the wavy interface are increased. It is found from the line scans of Cu/Al welding interface that element diffusion with a length of around 2 μm is occurred without interface melting. Therefore

the bonding mechanism of the copper-aluminum joints is mainly classified into following two aspects:the formation of atomic bonding at the interface due to element diffusion

and the formation of metallurgical bonding due to intense plastic deformation caused by high-speed collision.

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