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Electromagnetic pulse crimping (EMPC) technology is expected to be applied to the connection of high-voltage (HV) wiring harnesses and terminals for electric vehicle (EV). As an important part of the EMPC system, the assembly of the field shaper and the coil can directly affect the effect of EMPC. An EMPC system was established in this work, including the control part, energy storage capacitor bank, discharge switch, coil, and field shaper. The relationship between structure parameters of the field shaper and the coil was analyzed through the EMPC experiment of Al tubes. The results showed that the relative position and height of field shaper and coil have no obvious effect on the deformation length of the Al tube. When the angle between the gap of the field shaper and the gap of the coil is 90°, the deformation of Al tube is the most uniform. When the total height of field shaper is slightly less than the welding coil, the crimping effect is the best. This work can help design the field shaper and the coil for EMPC.

Electromagnetic pulse spot welding technology (EPSW) has great application prospects in the field of electric vehicles due to the realization of spot welding without gasket. The EPSW of Cu/Al alloy in this article is carried out in two steps. The first step uses electromagnetic force to pre-process the aluminum plate to punch a hump through electromagnetic pulse forming (EMPF). The second step uses electromagnetic force to realize spot welding between the hump and the copper plate. This article studied effects of stamping and spot welding with discharge voltage between 10 kV and 15 kV and compared welding effects of spot welding with coils of different widths. The results show: electromagnetic pulse spot welding technology without gasket was realized; the higher the discharge voltage, the better the stamping effect and spot welding performance; the wide coil can achieve a flat welding interface while the narrow coil can achieve reliable connection at a lower discharge voltage.

Limited by the current capacity of the discharge switch, the amplitude of the circuit discharge pulse current of electromagnetic pulse welding (EMPW) system is at a relatively low level, which greatly limits the application range of the EMPW technology. In this paper, the trigger vacuum switch (TVS) was selected as the discharge switch, and the double-switch synchronous conduction scheme was proposed. Based on two 20 kV/28 kJ single-switch electromagnetic pulse generation modular, a 20 kV/56 kJ double-switch electromagnetic pulse system was designed, which could generate a pulse current with the amplitude peak value of 360 kA when the charging voltage was 16 kV. Finally, the effective welding of 1 mm Mg/Al alloy plates was realized.