2. 2

3. Explosion welding is a solid-
state process that produces a
high velocity interaction of
dissimilar metals by a
controlled detonation.
Oxides found on material
surfaces must be removed by
effacement or dispersion.
Surface atoms of two joining Explosion bonding process.
metals must come into
intimate contact to achieve
metallic bond

4. Prime component is Detonation
placed either parallel or
at an angle to the base.
Explosive is distributed Weld
Prime
component
over top surface of Jet
Base
prime component. component
Action between components
Upon detonation, prime during explosion welding.
component collides
with base component to
complete welding.

5. Variables:
Explosive Pressure
These are Controlled By:
= Plate density
V = charge velocity

6. Experiment Results with Stainless steel as a flyer plate material
in parallel condition with ANFO explosive
Flyer Plate Measured Explosive Detonator
Test Stand-off
thickness Flyer Velocity Thickness velocity Vd Results
No. (mm)
(mm) (m/s) (mm) (m/s)
1 3 280 3 107 2050 Wavy
2 3 380 6 107 2050 Shallow waves
3 6 210 3 135 2250 Mostly un-bonded
4 6 250 6 135 2250 Partial bonding
5 12 245 6 235 2400 Partial bonding
6 12 300 12 235 2400 Wavy interface

7. Results from ABAQUS model:
Predicted Predicted Predicted
Measured Predicted
Test Collision maximum maximum
Flyer Velocity Flyer Velocity
No. Velocity Pressure shear
(m/s) (m/s)
(m/s) (GPa) stress (GPa)
1 300 294 2250 5.28617 0.264
2 330 324 2250 5.81482 0.290
3 245 337 2400 4.26927 0.213
4 300 310 2400 5.55757 0.277
5 340 358 2400 6.39333 0.319
6 400 394 2400 7.01322 0.350

8. flyer plate eventually attained a
terminal velocity for sufficiently
large stand-off distance
vertical velocity profile for the
flyer obtained from the ABAQUS
analyses are shown in red in Fig.
velocity increases from zero to its
highest at the collision point and
then the velocity reaches zero
Vertical velocity of flyer and base plate

9. Contact pressures are
about 107 Pa
Highest pressure is at
collision of the order of
109 Pa
Pressure profiles of flyer and base plates at
Contact pressure (normal to surface)
one instant in time

10. Parallel arrangements – pressure contour
Inclined arrangements – pressure contour

11. Pressure gradient is
negative ahead of a
stagnation point and
positive behind.
Decreasing from zero at
infinity to a minimum
value and reaching again
at x = 0; to rise to a
maximum positive value
behind the collision point.
Pressure gradient profiles of flyer plate at 0.3
m from the edges of the plates

12. Shear stress profiles of flyer and base Normal stress profiles of flyer and base
plates – parallel geometry plates

13. Normal stress contours –
Parallel arrangements
Normal stress contours –
Inclined arrangements

14. Relationships between operational conditions and physical
parameters, such as local stresses, strains and particle
velocities which determine the success or failure of the weld
were identified.
Bonding is dependent on the level of induced plastic strain
in the two materials exceeding a threshold level. In the case
of simulations of the bonded plates the shear stresses were
of opposite sign but had the same sign for non-welded
plates.

15. 1. S.A.A. Akbari Mousavi, S.T.S. Al-Hassani , “Finite element simulation of
explosively-driven plate impact with application to explosive welding”
Materials and Design 29 (2008) 1–19.
2. A.A. Akbari Mousavi, S.J. Burley, S.T.S. Al-Hassani, “Simulation of
explosive welding using the Williamsburg equation of state to model
low detonation velocity explosives”, International Journal of Impact
Engineering 31 (2005) 719–734.
3. Yuxin Wang, H.G. Beom , Ming Sun, Song Lin, “Numerical simulation of
explosive welding using the material point method”, International
Journal of Impact Engineering 38 (2011) 51e60.
4. A.A. Akbari Mousavia, S.T.S. Al-Hassani, “Numerical and experimental
studies of the mechanism of the wavy interface formations in
explosive/impact welding”, Journal of the Mechanics and Physics of
Solids 53 (2005) 2501–2528