Design of explosively welded Fe–Al multilayer laminated composite pipes: A critical microscopy analysis of stand-off distance and post-weld heat treatment effects on interface properties

This study examined the microstructure and mechanical properties of explosively welded (EXW) Fe–Al multilayer laminated composite pipes, specifically SS321/AA1050/AA5083, with varying stand-off distances (SD) and post-weld heat treatments (PWHT). Findings revealed that higher collision forces at higher-SD produced a wavy interface with finer grains at the AA1050/AA5083 interface. In contrast, lower-SD yielded a smooth, flat interface. At the SS321/AA1050 interface, collision energy resulted in the formation of an uneven composite reaction layer comprising multiple intermetallics. Analysis of the SS321/AA1050 interface revealed that an increase in the PWHT temperature results in diffusion toward the reaction layer, transforming the unevenly Al-rich and Fe-rich phases into a uniform Al 85 (Fe,Cr,Ni) 15 solid solution. The increase in the fraction of this phase made the reaction layer more brittle. At the AA1050/AA5083 interface, PWHT at higher temperatures caused a significant hardness decline extending further from the interface in samples with higher-SD. On the SS321 side of the laminated composite, higher SD resulted in higher kernel average misorientation (KAM) and increased hardness. Despite a decrease in hardness after PWHT at 350 °C, the hardness gradient from the matrix to the interface in laminates with higher SD remained relatively unaffected, whereas the lower SD counterparts experienced a noticeable stress relief.