Depiction of interfacial characteristic changes during impact welding using computational methods: Comparison between Arbitrary Lagrangian - Eulerian and Eulerian simulations

•Complex interfacial phenomena and potential causes in high speed impact welding are investigated using numerical simulations.•ALE simulations cannot adequately reproduce the interfacial features; but, Eulerian method reveals its superior capabilities.•Eulerian simulations also predict the potential cause of interfacial defects due to localized increase in temperature.•Agreements between experimental and Eulerian simulations are utilizable to virtually identify the weldability window.

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.

Graphical abstractAbstract figure: numerical simulation of interface behaviour in impact welding. Limitations of ALE method and potential of Eulerian method.Figure optionsDownload full-size imageDownload as PowerPoint slide