Electromagnetic compression of tubular profiles with high electrical conductivity is an innovative joining process for the manufacturing of lightweight structures. Taking conventional interference fits into account, the contact area s influence on the joint s quality seems to be of significance, as e.g. the contact area and the friction coefficient between the joining partners determine an allowed axial load or torsional momentum proportionally. Therefore, different contact area surfaces were prepared by shot peening and different machining operations and strategies. The mandrel s surfaces were prepared by shot peening with glass beads and Al2O3 particles. Alternatively, preparation was done using simultaneous five axis milling, because potential joining partners in lightweight frame structures within the Transregional Collaborative Research Centre SFB/TR10 would be manufactured similarly. After that, the manufactured surfaces were characterized by measuring the surface roughness and using confocal whitelight microscopy. After joining by electromagnetic compression, the influence of different mandrel s surface conditions on the joint s mechanical properties were analyzed by tensile tests. Finally, conclusions and design rules for the manufacturing of joints by electromagnetic compression are given.
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