A robust process-structure model for predicting the joint interface structure in impact welding

Gupta, Varun; Lee, Taeseon; Vivek, Anupam; Choi, Kyoo Sil; Mao, Yu; Sun, Xin; Daehn, Glenn

doi:10.1016/j.jmatprotec.2018.08.047

Title: A robust process-structure model for predicting the joint interface structure in impact welding

Abstract

The impact welding is gaining popularity in joining of dissimilar metals as any intermetallics are often very thin or discontinous with little to no heat affected zone resulting from the process. This work focuses on a recently developed impact welding technique, known as the Vaporizing Foil Actuator Welding (VFAW), which uses the pressure created from the electrically driven rapid vaporization of a thin metallic conductor to drive the flyer. A typical characteristic of an impact-welded joint is the wavy weld interface which is attributed to the complex interfacial kinematics resulting from the high-speed oblique impact of the metal plates. A numerical simulation framework based on the finite element method (FEM) with Eulerian formalism is developed to model the high-speed impact between the metal plates. The model accounts for the thermomechanical interactions in the process and captures the complex interfacial deformations. A thorough validation of the model is achieved by comparing the wave characteristics obtained from numerical simulations with the experimental results from vaporizing foil actuator welding. The amplitude and wavelength of the interfacial waves and the resulting joint microstructure is shown to be strongly dependent on the process conditions and the specific material system, which is well captured by themore » model.« less

Authors:

^[1]; Lee, Taeseon ^[2];

^[2]; Choi, Kyoo Sil ^[1]; Mao, Yu ^[2]; Sun, Xin ^[3]; Daehn, Glenn ^[2]

Pacific Northwest National Lab. (PNNL), Richland, WA (United States)
The Ohio State Univ., Columbus, OH (United States). Dept. of Materials Science and Engineering
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)

Publication Date:: Fri Feb 01 00:00:00 EST 2019

Research Org.:: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); Pacific Northwest National Lab. (PNNL), Richland, WA (United States)

Sponsoring Org.:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Transportation Office. Vehicle Technologies Office; USDOE

OSTI Identifier:: 1813282

Alternate Identifier(s):: OSTI ID: 1490321

Report Number(s):: PNNL-SA-132656
Journal ID: ISSN 0924-0136

Grant/Contract Number:: AC05-00OR22725; AC05-76RL01830

Resource Type:: Accepted Manuscript

Journal Name:: Journal of Materials Processing Technology

Additional Journal Information:: Journal Volume: 264; Journal Issue: -; Journal ID: ISSN 0924-0136

Publisher:: Elsevier

Country of Publication:: United States

Language:: English

Subject:: 97 MATHEMATICS AND COMPUTING; 42 ENGINEERING; Eulerian formulation; finite element method; dissimilar materials joining

Citation Formats


                    Gupta, Varun, Lee, Taeseon, Vivek, Anupam, Choi, Kyoo Sil, Mao, Yu, Sun, Xin, and Daehn, Glenn. A robust process-structure model for predicting the joint interface structure in impact welding.  United States: N. p., 2019. 
Web.  doi:10.1016/j.jmatprotec.2018.08.047.

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                    Gupta, Varun, Lee, Taeseon, Vivek, Anupam, Choi, Kyoo Sil, Mao, Yu, Sun, Xin, & Daehn, Glenn. A robust process-structure model for predicting the joint interface structure in impact welding.  United States.  https://doi.org/10.1016/j.jmatprotec.2018.08.047

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                    Gupta, Varun, Lee, Taeseon, Vivek, Anupam, Choi, Kyoo Sil, Mao, Yu, Sun, Xin, and Daehn, Glenn. Fri .  
"A robust process-structure model for predicting the joint interface structure in impact welding".  United States.  https://doi.org/10.1016/j.jmatprotec.2018.08.047.  https://www.osti.gov/servlets/purl/1813282.

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@article{osti_1813282,

  title        = {A robust process-structure model for predicting the joint interface structure in impact welding},

  author       = {Gupta, Varun and Lee, Taeseon and Vivek, Anupam and Choi, Kyoo Sil and Mao, Yu and Sun, Xin and Daehn, Glenn},

  abstractNote = {The impact welding is gaining popularity in joining of dissimilar metals as any intermetallics are often very thin or discontinous with little to no heat affected zone resulting from the process. This work focuses on a recently developed impact welding technique, known as the Vaporizing Foil Actuator Welding (VFAW), which uses the pressure created from the electrically driven rapid vaporization of a thin metallic conductor to drive the flyer. A typical characteristic of an impact-welded joint is the wavy weld interface which is attributed to the complex interfacial kinematics resulting from the high-speed oblique impact of the metal plates. A numerical simulation framework based on the finite element method (FEM) with Eulerian formalism is developed to model the high-speed impact between the metal plates. The model accounts for the thermomechanical interactions in the process and captures the complex interfacial deformations. A thorough validation of the model is achieved by comparing the wave characteristics obtained from numerical simulations with the experimental results from vaporizing foil actuator welding. The amplitude and wavelength of the interfacial waves and the resulting joint microstructure is shown to be strongly dependent on the process conditions and the specific material system, which is well captured by the model.},

  doi          = {10.1016/j.jmatprotec.2018.08.047},

  journal      = {Journal of Materials Processing Technology},

  number       = -,

  volume       = 264,

  place        = {United States},

  year         = {Fri Feb 01 00:00:00 EST 2019},

  month        = {Fri Feb 01 00:00:00 EST 2019}

}

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Computer Methods in Applied Mechanics and Engineering, Vol. 193, Issue 39-41
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Impact Welding of Aluminum Alloy 6061 to Dual Phase 780 Steel Using Vaporizing Foil Actuator
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Interfacial kinematics and governing mechanisms under the influence of high strain rate impact conditions: Numerical computations of experimental observations
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Raoelison, R. N.; Sapanathan, T.; Padayodi, E.
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Depiction of interfacial morphology in impact welded Ti/Cu bimetallic systems using smoothed particle hydrodynamics
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Nassiri, Ali; Vivek, Anupam; Abke, Tim
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Joining of titanium/stainless steel by explosive welding and effect on interface
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Numerical investigation of CP-Ti & Cu110 impact welding using smoothed particle hydrodynamics and arbitrary Lagrangian-Eulerian methods
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Journal of Manufacturing Processes, Vol. 28
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Arbitrary Lagrangian–Eulerian finite element simulation and experimental investigation of wavy interfacial morphology during high velocity impact welding
journal, December 2015

Nassiri, Ali; Chini, Greg; Vivek, Anupam
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Works referencing / citing this record:

High-Velocity Impact Welding Process: A Review
journal, January 2019

Wang, Huimin; Wang, Yuliang
Metals, Vol. 9, Issue 2
DOI: 10.3390/met9020144

Simulation and Experimental Comparison of Laser Impact Welding with a Plasma Pressure Model
journal, November 2019

Sadeh, Sepehr; Gleason, Glenn H.; Hatamleh, Mohammad I.
Metals, Vol. 9, Issue 11
DOI: 10.3390/met9111196

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Similar Records

Title: A robust process-structure model for predicting the joint interface structure in impact welding

Abstract

Citation Formats

Contact in a multi-material Eulerian finite element formulation journal, October 2004

Wave formation in explosive welding journal, April 1968

Impact Welding of Aluminum Alloy 6061 to Dual Phase 780 Steel Using Vaporizing Foil Actuator conference, April 2015

Mechanism of bond zone wave formation in explosion-clad metals journal, November 1971

Wave formation mechanism in magnetic pulse welding journal, April 2010

Accessing collision welding process window for titanium/copper welds with vaporizing foil actuators and grooved targets journal, August 2014

Prediction of the Wavelength of Interface Waves in Symmetric Explosive Welding journal, April 1976

Vaporizing foil actuator: A tool for collision welding journal, December 2013

Laser impact welding application in joining aluminum to titanium journal, August 2016

Computational methods in Lagrangian and Eulerian hydrocodes journal, September 1992

Interfacial kinematics and governing mechanisms under the influence of high strain rate impact conditions: Numerical computations of experimental observations journal, November 2016

On the transition from a waveless to a wavy interface in explosive welding journal, July 1987

Depiction of interfacial morphology in impact welded Ti/Cu bimetallic systems using smoothed particle hydrodynamics journal, June 2017

Effect of the initial parameters on the process of wave formation in explosive welding journal, January 1969

In-situ observations of single micro-particle impact bonding journal, March 2018

Joining of titanium/stainless steel by explosive welding and effect on interface journal, November 2005

Numerical study of the mechanism of explosive/impact welding using Smoothed Particle Hydrodynamics method journal, March 2012

Evaluation of Flow and Failure Properties of Treated 4130 Steel journal, April 2016

Numerical investigation of CP-Ti & Cu110 impact welding using smoothed particle hydrodynamics and arbitrary Lagrangian-Eulerian methods journal, August 2017

Arbitrary Lagrangian–Eulerian finite element simulation and experimental investigation of wavy interfacial morphology during high velocity impact welding journal, December 2015

Permanent Periodic Surface Deformations Due to a Traveling Jet journal, December 1961

Surface effects with oblique collisions between metallic plates journal, May 1974

Design for quality explosive welding journal, July 1992

High-Velocity Impact Welding Process: A Review journal, January 2019

Simulation and Experimental Comparison of Laser Impact Welding with a Plasma Pressure Model journal, November 2019

Contact in a multi-material Eulerian finite element formulation
journal, October 2004

Wave formation in explosive welding
journal, April 1968

Impact Welding of Aluminum Alloy 6061 to Dual Phase 780 Steel Using Vaporizing Foil Actuator
conference, April 2015

Mechanism of bond zone wave formation in explosion-clad metals
journal, November 1971

Wave formation mechanism in magnetic pulse welding
journal, April 2010

Accessing collision welding process window for titanium/copper welds with vaporizing foil actuators and grooved targets
journal, August 2014

Prediction of the Wavelength of Interface Waves in Symmetric Explosive Welding
journal, April 1976

Vaporizing foil actuator: A tool for collision welding
journal, December 2013

Laser impact welding application in joining aluminum to titanium
journal, August 2016

Computational methods in Lagrangian and Eulerian hydrocodes
journal, September 1992

Interfacial kinematics and governing mechanisms under the influence of high strain rate impact conditions: Numerical computations of experimental observations
journal, November 2016

On the transition from a waveless to a wavy interface in explosive welding
journal, July 1987

Depiction of interfacial morphology in impact welded Ti/Cu bimetallic systems using smoothed particle hydrodynamics
journal, June 2017

Effect of the initial parameters on the process of wave formation in explosive welding
journal, January 1969

In-situ observations of single micro-particle impact bonding
journal, March 2018

Joining of titanium/stainless steel by explosive welding and effect on interface
journal, November 2005

Numerical study of the mechanism of explosive/impact welding using Smoothed Particle Hydrodynamics method
journal, March 2012

Evaluation of Flow and Failure Properties of Treated 4130 Steel
journal, April 2016

Numerical investigation of CP-Ti & Cu110 impact welding using smoothed particle hydrodynamics and arbitrary Lagrangian-Eulerian methods
journal, August 2017

Arbitrary Lagrangian–Eulerian finite element simulation and experimental investigation of wavy interfacial morphology during high velocity impact welding
journal, December 2015

Permanent Periodic Surface Deformations Due to a Traveling Jet
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Surface effects with oblique collisions between metallic plates
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Design for quality explosive welding
journal, July 1992

High-Velocity Impact Welding Process: A Review
journal, January 2019

Simulation and Experimental Comparison of Laser Impact Welding with a Plasma Pressure Model
journal, November 2019