Upset Resistance Welding of a Microcomposite Cu-Nb Conductor for Pulsed Power Applications

The present study offers an experimental investigation into the welding of Cu–Nb wire using upset resistance welding. The aim is to examine the structure, as well as the electrical and mechanical properties, of Cu–Nb conductor joints produced by this method, which are intended for use in coils in pulsed magnetic systems. Analysis of the joint structure revealed that it was free from welding defects. The welded joint demonstrated a negligible change in electrical resistance while retaining sufficient ultimate strength and plasticity comparable to the base material. The tensile strength of the welded sample was found to be 620 MPa. The heat-affected zone is narrow, and the heating temperature is lower than the melting point of the composite material. Therefore, welding occurs in the solid phase without remelting the Cu–Nb composite wire or destroying its unique microstructure. Thus, upset welding is a promising technology for use in solenoid terminal connections with external electrical circuits that are not directly exposed to the high magnetic or tensile forces generated inside a solenoid of a pulsed magnet system.