Multiscale Simulation of Crack Propagation in Impact-Welded Al4Cu9 Alloy Based on Cohesive Zone Model
Year: 2025
Type: article
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 validation for the traction–separation (T-S) parameters extracted from MD and mapped into the FE model. The results indicate that composite defects (blunt crack + void) cause a significantly greater reduction in fracture energy and stress intensity factor than single defects and that defect effects outweigh temperature effects within the range of 200–500 K. The experimentally observed crack initiation locations were in strong agreement with simulation predictions. This integrated simulation–experiment approach not only elucidates the multiscale fracture mechanisms of the Al4Cu9 interface but also provides a physically validated basis for the reliability assessment and optimization of aerospace Cu/Al welded structures.
Source: Materials
DOI: 10.3390/ma18214862
Authors: Rongqing Luo, Dingjun Xiao, Guangzhao Pei, Haixia Yan, Sen Han, Jiajie Jiang, Miaomiao Zhang
Institution: Southwest University of Science and Technology
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $3,137
OpenAlex ID: W4415489754