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

Abstract Finite element simulations of high strain rate forming processes are of significant interest to industry, but are challenging due to the coupled physics and dynamic nature of the processes. For instance, in high velocity impact welding, extremely high plastic strain regions develop. Thus, a traditional pure Lagrangian analysis is not able to accurately model the process due to excessive element distortion near the contact zone. In this study, the Arbitrary Lagrangian–Eulerian method (ALE) was used to simulate an impact welding process for two Al6061-T6 plates. The ALE method was able to numerically predict the temperature at the interface as well as the necessary process parameters to achieve a wavy morphology at the interface of the materials which is assumed to be a characteristic of a quality impact weld. This allowed the prediction of a weldability window, including separate regions for melting and purely solid state welds. To validate the proposed numerical model and wavy morphology regions, experimental tests with a Vaporizing Foil Actuator Welding (VFAW) process were conducted including Photon Doppler Velocimetry (PDV) measurements of the impact velocity. The numerical results were in good agreement with the experimental tests including the temperature prediction and interfacial melting observed through microstructural analyses.