A comparative study on waveform prediction between SPH and S-ALE methods in impact welding

To explore the optimal method for simulating impact welding, we compared detailedly the smoothed particle hydrodynamics (SPH) and structured arbitrary Lagrangian-Eulerian (S-ALE) methods in predicting bonding interface. Based on the experimental results of Cu-Q235 steel atmospheric explosive welding, an in-depth analysis was presented. The results show that the SPH and S-ALE methods converged at element sizes of 2.5 and 2 mu m, respectively. When the element size was further reduced to 0.5 % of the wavelength, the errors of both methods were less than 5 %. Benefiting from the gradient mesh, the efficiency of the S-ALE method was 2-4 times that of the SPH method at the same element size. With the addition of the gas medium, the S-ALE method derived the formation mechanism of the gap gas shockwave and indicated that the pressure distribution is not uniform. Furthermore, the local high pressure of the gas shockwave prevents the vortex closure during the wave formation, generating the pore. The calculated pressure and velocity of the wavefront were 20 MPa and 3500 m s- 1, respectively. In conclusion, the SPH is suitable for fast previewing waveform interfaces, while the S-ALE method has the advantage of capturing fine waveform structures under various environmental conditions.