Multiscale Simulation of Crack Propagation in Impact-Welded Al4Cu9 Alloy Based on Cohesive Zone Model
Rongqing Luo, Dingjun Xiao, Guangzhao Pei, Haixia Yan, Sen Han, Jiajie Jiang, Miaomiao Zhang
TL;DR
This study combines simulations and experiments to understand how cracks spread in impact-welded Cu/Al joints, focusing on the Al4Cu9 interface.
Contribution
The paper introduces an integrated multiscale approach combining MD, FE, and CZM with experimental validation to study crack propagation in Cu/Al joints.
Findings
Composite defects reduce fracture energy and stress intensity more than single defects.
Defect effects are more significant than temperature effects in the studied range.
Simulation predictions align with experimentally observed crack initiation locations.
Abstract
The fracture behavior of the Al4Cu9 intermetallic compound at the interface of impact-welded Cu/Al joints remains insufficiently explored through integrated multiscale modeling and experimental validation. In this study, molecular dynamic (MD) simulations, finite element (FE) analysis implemented in ABAQUS (version 2020) and a cohesive zone model (CZM) were combined with optical microscopy (OM) and scanning electron microscopy (SEM) observations of the interface and crack initiation zones in impact-welded Cu/Al specimens to investigate crack propagation mechanisms under different defect configurations. The experimental specimens consisted of 1060 aluminum (Al) and oxygen-free high-conductivity (OFHC) copper, fabricated via impact welding and subsequently annealed at 250 °C for 100 h. The interfacial morphology and crack initiation features obtained from OM and SEM provided direct…
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Taxonomy
TopicsMetal Forming Simulation Techniques · Numerical methods in engineering · Advanced Welding Techniques Analysis