Numerical and experimental studies of the mechanism of the wavy interface formations in explosive/impact welding

Explosively driven impact welding is a true example of multidisciplinary research as the phenomena associated with it fall under the various branches of engineering science. A great deal of the work in, and collaboration between various specialised fields have been expended on the subject. However, a comprehensive quantitative theory capable of giving an accurate description and prediction of the parameters and of the characteristic features of explosively welded components does not exist. Most of the investigators considered the welding process as a solid state welding process, but some believed that the process is a fusion welding process. Interfacial waves are the most discussed aspect of explosive welding. The presence of jet in the collision region, and the transient fluid-like behaviour under high pressure have led many investigators to seek an explanation and a characterisation of these waves in terms of a flow mechanics of one kind or another. In this study, part of the welding process was numerically analysed. A finite difference engineering package was used to model the oblique impact of a thin flyer plate on a relatively thick base. The results were validated by data from carefully controlled experiments using a pneumatic gun. Straight and wavy interfaces and jetting phenomena were modelled, and the magnitude of the waves and the velocity of jet predicted. The numerical analysis predicted a hump ahead of the collision point. Wave formation appears to be the result of variations in the velocity distribution at the collision point and periodic disturbances of the materials. Higher values of plastic strain were predicted in wavy interfaces. Bonding was found to be a solid state welding process. Phase changes which occur may be due to high temperatures (but less than the melting temperature) at the collision point.