Journal of Materials Processing Technology 177 (2006) 266–269

Characterisation of extruded magnesium profiles

for electromagnetic joining
V. Psyk ∗ , C. Beerwald, A. Klaus, M. Kleiner
Institute of Forming Technology and Lightweight Construction, University of Dortmund, Baroper Str. 301, 44221 Dortmund, Germany

Abstract
Electromagnetic compression is a suitable technology for the processing of hollow profiles made of aluminium alloys. In order to evaluate its
suitability for magnesium profiles, different extruded magnesium alloys have been characterised. Important requirements on the tube material are,
on the one hand, a high electrical conductivity and, on the other hand, a good formability. Thus, the evaluation of the magnesium alloys was done
focusing particularly on these requirements.
© 2006 Elsevier B.V. All rights reserved.

Keywords: Electromagnetic joining; Magnesium profiles; Conductivity; Formability

1. Introduction
The growing interest in lightweight construction concepts
requires a systematic development and investigation of suitable
lightweight construction materials, on the one hand, and appro-
priate production technologies for the processing of these mate-
rials, on the other hand. In this context, electromagnetic forming
(EMF) represents an interesting technique. EMF is a non-contact
high speed process using the energy density of pulsed magnetic
fields to apply forces to workpieces made of electrically high
conductive materials. Depending on geometry and arrangement
of tool coil and workpiece, the process can be used for form-
ing sheet metal [1–3] and for expansion as well as compression
of tubes and other hollow profiles. Especially over recent years
the potential for the processing of aluminium alloys by means
of electromagnetic forming has been investigated [4–7]. Owing
to the advantageous ratio of strength and density, magnesium
alloys offer an even higher potential for lightweight construc-
tion concepts than aluminium alloys. However, the application
of extruded magnesium profiles is still limited. The reasons are,
among others, problems in the forming and joining technology
as for example:
• the limited formability of most magnesium alloys, especially
in cold forming processes [8], and
• the limited possibilities to join hybrid material connections.
∗ Corresponding author. Tel.: +49 231 755 5238; fax: +49 231 755 2489.
E-mail address: verena.psyk@iul.uni-dortmund.de (V. Psyk).
One aim of a research project founded within the DFG prior-
ity programme 1168 is to analyse the suitability of electromag-
netic forming for the processing of such semi-finished parts.
These investigations are done in close cooperation between the
Institute of Materials Science (IW), University of Hannover, and
the Institute of Forming Technology and Lightweight construc-
tion (IUL), University of Dortmund. Here, the adaptation of the
process-specific requirements, on the one hand, and the material
properties, on the other hand, are of significant importance.
2. Process principle and related requirements on the
material
In Fig. 1, the typical setup of workpiece, tool coil, and forming
machine is shown for the electromagnetic tube compression. In
the equivalent circuit diagram this setup can be represented by a
resonant circuit in which the forming machine is symbolised by
the capacitor C, the inner resistance R, and the inner inductance
L. The tool coil, including the tubular workpiece, can be seen
as the consumer load. The sudden discharge of the capacitor
causes a damped sinusoidal current I(t) through the tool coil,
establishing an according magnetic field H(r,z,t) within several
microseconds. Thereby, a current is induced in the workpiece
which is directed in the opposite direction of the coil current
and shields the magnetic field. The energy density of a magnetic
field represents a pressure acting orthogonal on the field. The
resulting pressure difference acting on the tube causes a plastic
radial deformation as soon as the yield strength of the workpiece
is exceeded.

0924-0136/$ – see front matter © 2006 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2006.03.211
 V. Psyk et al. / Journal of Materials Processing Technology 177 (2006) 266–269
Fig. 1. Principle of the electromagnetic compression process.
During further proceeding of the process the magnetic field
penetrates into the workpiece. This effect is significantly influ-
enced by the frequency of the discharging current, the workpiece
geometry, characterised by radius and wall thickness, and the
electrical conductivity of the material [9]. According to [10],
the magnetic pressure p(z,t) can be calculated from the magnetic
field outside the workpiece Ha (t,z), the penetrated magnetic field
Hi (t,z), and the permeability µ0 using the following equation:
p(z, t) = 21 µ0 (Ha2 (t, z) − Hi2 (t, z))
According to the described principle, the following essential
requirements on the tube material can be concluded:
• A closed cross section geometry of the workpiece is essential
for the working mechanism of the EMF process.
• A high electrical conductivity of the workpiece is necessary
to allow a high efficiency of the process.
• A sufficient formability of the material under the highly
dynamic conditions of the EMF process is necessary.
With special regard to these requirements the suitability of
different magnesium alloys for the EMF process was examined.
Thereby, only extruded tube material (diameter: 40 mm; wall
thickness: 2 mm) has been used, guaranteeing a closed cross
section geometry. For the investigations the low alloyed material
ZEK100, the standard alloy AZ31, and the alloy AZ31, modified
by adding 0.2% calcium by IW, have been considered [11]. The
addition of a small amount of calcium was done in order to effect
a grain refinement [8] and, thus, to improve the formability. On
the other hand, the addition of any alloying element usually
decreases the electrical conductivity [12] so that the positive
and negative effects of this modification need to be evaluated.
3. Investigation of the electrical conductivity
In order to determine the electrical conductivity of the dif-
ferent alloys, measurements have been done according to DIN
IEC 468. The results are listed in Table 1 in comparison to typi-
cal values of pure magnesium, copper, pure aluminium, and an
aluminium alloy.
267
Table 1
Electrical conductivity
Material Electrical conductivity (MS/m)
AZ31 ∼9–11
AZ31 + 0.2% Ca ∼10–11
ZEK100 ∼18
Pure magnesium ∼22
Copper ∼56
Pure aluminium ∼36
AA5754 ∼17–19
The comparison of AZ31 and AZ31 + 0.2% Ca shows no sig-
nificant difference. Thus, it can be concluded that the reduction
of the conductivity, caused by the small amount of calcium, cor-
responds to the alteration between different batches of AZ31
and to the accuracy of the measurement, respectively. In con-
trast, the result determined for ZEK100 is much higher. The
conductivity of pure magnesium represents an upper limit for
all magnesium alloys and due to the micro-alloying technique
a high value could be adhered. The measured conductivity of
ZEK100 is similar to the one of AA5754, which can be success-
fully processed by means of electromagnetic compression [6,7],
although it is a relatively low-conductive aluminium alloy.
For the further evaluation of the conductivity the influence
on the current and the magnetic pressure, respectively, needs
(1)
to be considered. Therefore, measured current curves using the
same EMF equipment (forming machine and tool coil), but dif-
ferent workpiece materials are compared in Fig. 2. On the basis
of these current curves the influence of the conductivity can
be determined, the current having a quadratic influence on the
pressure. A simple lower estimation neglecting the penetration
Fig. 2. Influence of the electrical conductivity on the coil current.
268 V. Psyk et al. / Journal of Materials Processing Technology 177 (2006) 266–269
of the magnetic field into the workpiece shows that an increase
in the conductivity from 10.0 to 17.8 MS/m leads to a pressure
increase of more than 12%.
4. Investigation of the formability
To quantify the formability of the two investigated magne-
sium alloys under different load cases, quasi-static tensile tests
and quasi-static hydraulic burst tests have been performed. In
order to detect the strain at failure under the process-specific con-
ditions of the EMF, several series of free EM-compression tests
have been performed. During these experiments the charging
energy was increased, leading to an increasing radial deforma-
tion and finally causing material failure in the form of cracking.
Subsequently, the compression of the smallest cross section
geometry was quantified by a coordinate measurement machine.
The mean strains at failure are summarised in Table 2.
Independent of the load case, the modification of AZ31 by
adding calcium led to the desired improvement of the forma-
bility. Furthermore, an even higher maximum strain could be
achieved for ZEK100. Here, the strain at failure achievable by
tensile tests corresponds well with values characteristic for alu-
minium alloys [13].
All investigated materials show a strongly anisotropic
behaviour for axial and tangential tensile load, which is typical
for extruded material. However, the achievable strain at failure
in the case of electromagnetic compression is relatively high
in comparison to the burst test. A possible explanation for this
effect is the high deformation velocity, which reduces localising
effects. This behaviour is known from investigations on alu-
minium alloys, showing that higher strain rates lead to reduced
wrinkling effects [6]. With regard to this correlation, it has to
be emphasised that the strain at failure, determined by free EM-
compression, is only valid for the chosen process parameters,
especially the course of the coil current. By applying a discharg-
ing current of higher frequency, the resulting forming velocity
can be further increased as long as the deformation process is
completed within the first half-wave of the current. According
to the previously described tendency, this might allow a further
extension of the forming limits.
In contrast to electromagnetically compressed aluminium
tubes, which usually fail due to wrinkling effects, the failure
criterion in case of the investigated magnesium specimens is
cracking. In Fig. 3, this failure mechanism is shown on the basis
of two exemplary specimens, the first one compressed with a rel-
atively low charging energy, causing only small deformations,
and the second one compressed using a higher charging energy,
leading to cracking.
Table 2
Strain at failure achievable for different load cases
Material Mean strain at failure determined by
Tensile tests (quasi-static) (%)
AZ31 ∼11
AZ31 + 0.2% Ca ∼21
ZEK100 ∼27
Fig. 3. Results of EM-compression tests.
The presented roundness plot shows clearly that already in
the case of the small deformation characteristic geometric devi-
ations occur, which are associated with the extrusion welds of
the semi-finished material. Independent of material and charging
energy the radial displacement of the tube is less pronounced in
the area of the extrusion welds compared to the area in between,
an effect that might be explained by a local variation of the
material strength.
In cases of higher deformation the cracking always occurs
in the area of the extrusion seams, too. This indicates a high
importance of the extrusion welds regarding the formability of
the specimen. Thus, the optimisation of the extrusion welds sug-
gests most likely a further extension of the forming limits.
5. Summary and outlook
Electromagnetical forming is a promising technology for the
processing of hollow profiles made of magnesium. Important
requirements set on the tube material by the process are high
electrical conductivity and good formability. With regard to
these aspects extruded magnesium alloys AZ31, AZ31 + 0.2%
Ca, and ZEK100 have been analysed in order to evaluate the
suitability for the electromagnetic forming. With regard to both
criteria ZEK100 proved to be most applicable and absolutely
comparable with some aluminium alloys which have been suc-
cessfully processed by means of EMF. However, the quality of
the extrusion welds was found to be of high importance regarding
the formability and the optimisation offers a further extension of
the forming limits. In order to achieve a deeper understanding
of the failure mechanism and to improve the extrusion welds,
microstructural investigations are required.
Burst tests (quasi-static) (%) EM-compression (%)
∼1 ∼11
∼6 ∼12
∼7 ∼15
 V. Psyk et al. / Journal of Materials Processing Technology 177 (2006) 266–269
Acknowledgements
The present study has been performed by the authors within
the priority programme 1168 “InnoMagTec” Project-No.
Kl 619/24-1 in cooperation with Project-No. Ba 851/59-1
of Professor Dr.-Ing. Bach, Institute of Materials Science,
University of Hannover. The authors gratefully acknowledge
the financial support of this research work by the German
Research Foundation (DFG).
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