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Effect of an interlayer on the microstructure and mechanical properties of explosively welded aluminum alloy-cast iron joints.

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Title: Effect of an interlayer on the microstructure and mechanical properties of explosively welded aluminum alloy-cast iron joints.
Authors: Sherpa, Bir Bahadur1 (AUTHOR) sherpa@mech.kumamoto-u.ac.jp, Nishi, Masatoshi1,2 (AUTHOR), Inao, Daisuke3 (AUTHOR), Tanaka, Shigeru1 (AUTHOR), Hokamoto, Kazuyuki1 (AUTHOR)
Source: International Journal of Advanced Manufacturing Technology. Apr2026, Vol. 143 Issue 11/12, p6269-6283. 15p.
Subjects: Explosive welding, Buffer layers, Mechanical behavior of materials, Aluminum alloys, Hydrodynamics, Microstructure, Shear strength, Cast-iron
Abstract: Joining aluminum alloys to brittle cast iron is challenging due to the high carbon content present in the form of graphite and the formation of a melting layer that degrades joint strength. In this study, an interlayer-assisted explosive welding approach was employed to mitigate these issues. The introduction of the interlayer reduced kinetic energy dissipation during impact. As a result, the interfacial bonding strength was improved. Direct welding of A5052/JIS G 5501 and A6061/JIS G 5501 resulted in shear strengths of 81 MPa and 104 MPa, respectively. The introduction of an interlayer increased the shear strength to 157 MPa and 192 MPa, corresponding to improvements of 93.8% and 84.6%. Large deformation under high pressure at extremely high strain rates is generally not expected in brittle cast iron due to its low ductility. A distinct wavy interface morphology was observed at the interlayer-cast iron interface. To investigate its formation, smoothed particle hydrodynamics (SPH) simulations were performed. The numerical results reproduced the experimentally observed interfacial features and confirmed the occurrence of significant interfacial deformation under high strain-rate conditions. Overall, the results demonstrate that the use of an interlayer is an effective strategy for enhancing the interfacial morphology and mechanical performance of aluminum alloy-cast iron explosive welds. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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DbLabel: Engineering Source
An: 193841302
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Items – Name: Title
  Label: Title
  Group: Ti
  Data: Effect of an interlayer on the microstructure and mechanical properties of explosively welded aluminum alloy-cast iron joints.
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  Data: <searchLink fieldCode="AR" term="%22Sherpa%2C+Bir+Bahadur%22">Sherpa, Bir Bahadur</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> sherpa@mech.kumamoto-u.ac.jp</i><br /><searchLink fieldCode="AR" term="%22Nishi%2C+Masatoshi%22">Nishi, Masatoshi</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Inao%2C+Daisuke%22">Inao, Daisuke</searchLink><relatesTo>3</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Tanaka%2C+Shigeru%22">Tanaka, Shigeru</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Hokamoto%2C+Kazuyuki%22">Hokamoto, Kazuyuki</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Advanced+Manufacturing+Technology%22">International Journal of Advanced Manufacturing Technology</searchLink>. Apr2026, Vol. 143 Issue 11/12, p6269-6283. 15p.
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  Data: <searchLink fieldCode="DE" term="%22Explosive+welding%22">Explosive welding</searchLink><br /><searchLink fieldCode="DE" term="%22Buffer+layers%22">Buffer layers</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink><br /><searchLink fieldCode="DE" term="%22Aluminum+alloys%22">Aluminum alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Hydrodynamics%22">Hydrodynamics</searchLink><br /><searchLink fieldCode="DE" term="%22Microstructure%22">Microstructure</searchLink><br /><searchLink fieldCode="DE" term="%22Shear+strength%22">Shear strength</searchLink><br /><searchLink fieldCode="DE" term="%22Cast-iron%22">Cast-iron</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Joining aluminum alloys to brittle cast iron is challenging due to the high carbon content present in the form of graphite and the formation of a melting layer that degrades joint strength. In this study, an interlayer-assisted explosive welding approach was employed to mitigate these issues. The introduction of the interlayer reduced kinetic energy dissipation during impact. As a result, the interfacial bonding strength was improved. Direct welding of A5052/JIS G 5501 and A6061/JIS G 5501 resulted in shear strengths of 81 MPa and 104 MPa, respectively. The introduction of an interlayer increased the shear strength to 157 MPa and 192 MPa, corresponding to improvements of 93.8% and 84.6%. Large deformation under high pressure at extremely high strain rates is generally not expected in brittle cast iron due to its low ductility. A distinct wavy interface morphology was observed at the interlayer-cast iron interface. To investigate its formation, smoothed particle hydrodynamics (SPH) simulations were performed. The numerical results reproduced the experimentally observed interfacial features and confirmed the occurrence of significant interfacial deformation under high strain-rate conditions. Overall, the results demonstrate that the use of an interlayer is an effective strategy for enhancing the interfacial morphology and mechanical performance of aluminum alloy-cast iron explosive welds. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Advanced Manufacturing Technology is the property of Springer Nature and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1007/s00170-026-17809-z
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      – Code: eng
        Text: English
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        PageCount: 15
        StartPage: 6269
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      – SubjectFull: Explosive welding
        Type: general
      – SubjectFull: Buffer layers
        Type: general
      – SubjectFull: Mechanical behavior of materials
        Type: general
      – SubjectFull: Aluminum alloys
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      – SubjectFull: Hydrodynamics
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      – SubjectFull: Microstructure
        Type: general
      – SubjectFull: Shear strength
        Type: general
      – SubjectFull: Cast-iron
        Type: general
    Titles:
      – TitleFull: Effect of an interlayer on the microstructure and mechanical properties of explosively welded aluminum alloy-cast iron joints.
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            NameFull: Sherpa, Bir Bahadur
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            NameFull: Nishi, Masatoshi
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            NameFull: Inao, Daisuke
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            NameFull: Tanaka, Shigeru
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            – D: 20
              M: 04
              Text: Apr2026
              Type: published
              Y: 2026
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              Value: 143
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