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Numerical Simulation of Impact Welding Processes with LS-DYNA

Pabst, Christian and Groche, Peter (2015):
Numerical Simulation of Impact Welding Processes with LS-DYNA.
In: 10th European LS-DYNA Conference, Würzburg, [Conference or Workshop Item]

Abstract

Impact welding enables metallurgical bonding even between dissimilar metals. The bond is formed during a high speed impact between the two workpieces to be joined under accurately defined conditions. In the application, the accelerating force is provided by an explosive (explosion welding, EXW) or by an electromagnetic field (electromagnetic pulse welding, EMPW). One workpiece is usually accelerated within a few millimeters up to 200 m/s and above. The impact and consequently the bond formation takes place in only a few microseconds which makes it hard to observe. In order to enable the observation of the two mentioned processes, a test rig has been built at the Institute for Production Engineering and Forming Machines which produces the impact purely mechanically. The numerical simulation with LS-DYNA is used to gain detailed insights into the process. Three phenomena, which are thought to have a significant effect on the bond formation, are currently investigated numerically: The supersonic displacement of the surrounding gaseous medium, the strains and strain rates at the bonding zone and the macroscopic flow of material. The results of the numerical simulations are compared to experimental and metallographic investigations. The comparison and fusion of the findings are used to draw new conclusions on the formation mechanisms of the bonding zone.

Item Type: Conference or Workshop Item
Erschienen: 2015
Creators: Pabst, Christian and Groche, Peter
Title: Numerical Simulation of Impact Welding Processes with LS-DYNA
Language: English
Abstract:

Impact welding enables metallurgical bonding even between dissimilar metals. The bond is formed during a high speed impact between the two workpieces to be joined under accurately defined conditions. In the application, the accelerating force is provided by an explosive (explosion welding, EXW) or by an electromagnetic field (electromagnetic pulse welding, EMPW). One workpiece is usually accelerated within a few millimeters up to 200 m/s and above. The impact and consequently the bond formation takes place in only a few microseconds which makes it hard to observe. In order to enable the observation of the two mentioned processes, a test rig has been built at the Institute for Production Engineering and Forming Machines which produces the impact purely mechanically. The numerical simulation with LS-DYNA is used to gain detailed insights into the process. Three phenomena, which are thought to have a significant effect on the bond formation, are currently investigated numerically: The supersonic displacement of the surrounding gaseous medium, the strains and strain rates at the bonding zone and the macroscopic flow of material. The results of the numerical simulations are compared to experimental and metallographic investigations. The comparison and fusion of the findings are used to draw new conclusions on the formation mechanisms of the bonding zone.

Uncontrolled Keywords: numerical simulation; impact welding; material parameters; process window
Divisions: 16 Department of Mechanical Engineering
16 Department of Mechanical Engineering > Institut für Produktionstechnik und Umformmaschinen (PtU)
Event Title: 10th European LS-DYNA Conference
Event Location: Würzburg
Date Deposited: 13 Jul 2015 07:29
Identification Number: 15 - 17 June
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