Papers abstract:

This paper investigates the development and evolution of various interfacial features during high-speed impact welding processes using numerical simulations. Arbitrary Lagrangian – Eulerian (ALE) and Eulerian computations are performed and compared with experimental features of welded joints. ALE method reveals poor mesh quality while the interface experiences severe shear deformation. Therefore, ALE simulations cannot accurately capture the morphological transition toward a wavy shape and cannot compute the successive jet formation from the interface. But the Eulerian method becomes a good alternative to overcome those limitations of the ALE method. Computed interfacial features using Eulerian simulations are agreed well with the experimental observations of various interfacial phenomena. The actual kinematics along the whole length of the weld including wavy pattern, localized plastic deformation and shear strain orientation are clearly reproduced. Eulerian simulation also provides understanding for the potential cause of defects that corresponds to the experimental observations, in terms of morphology and site occurrence.

Product Overview:
This tutorial provides step-by-step guidance on simulating impact welding between two aluminum pieces using Abaqus software. It follows the methodology described in the ISI paper but modifies the approach by using different formulations and parameter adjustments. The study investigates the evolution of interfacial features during high-speed impact welding (HSIW) using numerical simulations. It compares the capabilities of Arbitrary Lagrangian-Eulerian (ALE) and Eulerian methods in predicting weld formation, interfacial wave morphology, and defects. Key simulation steps include:

• The Johnson-Cook plasticity model effectively captures the deformation and strain behavior of aluminum under high-speed impact conditions.
• Temperature-dependent material properties significantly affect weld formation and quality.
• ALE Method:
  • Can simulate early-stage bonding but struggles with severe shear deformation.
  • Fails to capture the full transition to a wavy interface due to mesh distortion.
• Eulerian Method:
  • More effective in tracking interfacial changes and reproducing experimental observations.
  • Accurately predicts interfacial wave formation, shear strain distribution, and plastic deformation.
  • Identifies defect-prone areas caused by localized heating.
  • The tutorial modifies the original ISI paper approach, opting for different formulations while maintaining physical accuracy.

In this tutorial, the interfacial characteristic changes during impact welding are simulated, according to data from the work of Sapanathan et al.