Simulation of mechanical and thermal behavior in explosive welding of aluminum 1050 to copper

Subject Areas : Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering

Hamid Reza Vahdatpour ¹ , Mohammad Reza Khanzadeh ^{2 *} , Hamid Bakhtiari ³ , Kamran Amini ⁴

1 - Faculty of Materials Engineering, Islamic Azad University Shahreza Branch, Isfahan, Iran.
2 - Department of Material Engineering,Mo.C., Islamic Azad University, Isfahan , Iran
3 - Materials and Energy Research Center, Ceramics Research Institute, Karaj, Iran
4 - Department of Mechanical Engineering, Kho.C., Islamic Azad University, Khomeinishahr, Iran

Received: 2025-02-14 Accepted : 2025-06-08 Published : 2025-09-02

Keywords: Explosive welding, Simulation, Stand-off distance, Aluminum-copper joint,

Abstract :

Explosive welding is a solid-state joining method used for bonding dissimilar metals. In this study, the effect of stand-off distance on the mechanical and thermal behavior of aluminum 1050 to copper joints was investigated using Abaqus 6.12. The Johnson-Cook model was used to simulate the mechanical response, and the Williams-Bourg equation of state modeled the explosive material. The results showed that increasing the stand-off distance from 1.5 mm to 5 mm increased the impact velocity of the flyer plate from 900 m/s to 1073 m/s, and raised the dynamic impact angle from 20.70° to 24.75°. Plastic strain in the collision area and peak pressure (exceeding several GPa) also increased with stand-off distance. Optical microscopy confirmed that higher stand-off distances led to vortex-like wave formations and localized melting at the interface. These findings provide valuable insights for optimizing explosive welding parameters to achieve stronger and more uniform joints.

References:


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