Effect of preset angle in explosive welding of aluminum-copper alloys

This study explores the influence of preset angle, α (0 and 3°), on the interface microstructure of aluminium (A6061-T6)-Copper Deoxidized High Residual Phosphorus (Cu-DHP) explosive weld joints. The weld joints obtained for a parallel configuration exhibited a characteristic wavy interface along with trapped jet formation, reflecting enhanced collision velocity and jetting behaviour. However, the introduction of preset angle (3°), resulted in a straight interface, indicating limited plastic deformation. Numerical simulation performed in ANSYS AUTODYN employing Smoothed Particle Hydrodynamics (SPH) determined a peak pressure of 3.9 X 104 MPa and 2.5 X 104 MPa in parallel (0°) and inclined (3°) configurations respectively. Similarly, the maximum temperature across the interface (1000 K and 780 K) and strain developed (1.1 and 1.4) during the process was observed for parallel and inclined configurations respectively. In addition, the experimental conditions attempted prevail within the successful regimes of weldability window comprising upper, lower, left and right boundaries, determined analytically.