Explosive welding of hollow-channel SUS304/Q235 bimetallic plates using compacted Fe-Sn powder mixture: functionally graded design and mechanism study

Explosive welding of hollow-channel SUS304/Q235 bimetallic plates using compacted Fe-Sn powder mixture: functionally graded design and mechanism study | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Explosive welding of hollow-channel SUS304/Q235 bimetallic plates using compacted Fe-Sn powder mixture: functionally graded design and mechanism study Yiyang Pan, Shuyang Zheng, Ming Yang, Jinxiang Wang, Yong Yu This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7626916/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 20 Apr, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Dissimilar metal hollow components are critical for aerospace and energy applications, but conventional explosive welding faces issues: flow channel collapse, weak interfacial bonding, and filler retention. This study proposes a groundbreaking solution using Fe-Sn functionally graded materials as filler, achieving synergistic optimization of localized high-strength support and low-temperature softening via controlled Fe/Sn volume ratios. Focused on explosive welding of SUS304/Q235 hollow flow channels, it investigates dynamic welding responses under varying Fe/Sn volume ratios through coupled ALE and SPH simulations, with experiments using parameters optimized through these simulations. It was found that increasing Fe content in filler improves uniformity of maximum and minimum pressures on the base plate, but the improvement slows down significantly when Fe content reaches a certain level. Considering filler extractability, an Fe-Sn ratio of 3:4 was determined as optimal formulation. The experiments produced samples with hardly any channel deformation and superior welding interface waveforms, confirming technical superiority of our approach. SPH simulations further elucidate the interface wave formation mechanism. It can be described as a result of the interaction of jetting and protrusions. This study pioneered a functionally graded filler design, successfully resolving geometric stability and interfacial integrity challenges in the explosion welding of thin-walled hollow components. Explosive welding Functionally graded materials Hollow channel ALE/SPH simulation Full Text Cite Share Download PDF Status: Published Journal Publication published 20 Apr, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Minor Revisions Needed 20 Mar, 2026 Reviewers agreed at journal 21 Sep, 2025 Reviewers invited by journal 21 Sep, 2025 Editor assigned by journal 19 Sep, 2025 First submitted to journal 18 Sep, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7626916","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":518164649,"identity":"cd1df18e-2a78-4f00-9394-639889b974f8","order_by":0,"name":"Yiyang Pan","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Yiyang","middleName":"","lastName":"Pan","suffix":""},{"id":518164650,"identity":"44b42cc6-ef86-4ff2-915a-e46f209bda5a","order_by":1,"name":"Shuyang 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This study proposes a groundbreaking solution using Fe-Sn functionally graded materials as filler, achieving synergistic optimization of localized high-strength support and low-temperature softening via controlled Fe/Sn volume ratios. Focused on explosive welding of SUS304/Q235 hollow flow channels, it investigates dynamic welding responses under varying Fe/Sn volume ratios through coupled ALE and SPH simulations, with experiments using parameters optimized through these simulations. It was found that increasing Fe content in filler improves uniformity of maximum and minimum pressures on the base plate, but the improvement slows down significantly when Fe content reaches a certain level. Considering filler extractability, an Fe-Sn ratio of 3:4 was determined as optimal formulation. The experiments produced samples with hardly any channel deformation and superior welding interface waveforms, confirming technical superiority of our approach. SPH simulations further elucidate the interface wave formation mechanism. It can be described as a result of the interaction of jetting and protrusions. This study pioneered a functionally graded filler design, successfully resolving geometric stability and interfacial integrity challenges in the explosion welding of thin-walled hollow components.\u003c/p\u003e","manuscriptTitle":"Explosive welding of hollow-channel SUS304/Q235 bimetallic plates using compacted Fe-Sn powder mixture: functionally graded design and mechanism study","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-10-01 09:02:34","doi":"10.21203/rs.3.rs-7626916/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Minor Revisions Needed","date":"2026-03-20T07:21:02+00:00","index":"","fulltext":""},{"type":"reviewerAgreed","content":"","date":"2025-09-22T02:08:18+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-09-21T04:01:23+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-09-19T23:47:32+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-09-18T09:34:07+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"f81aa26d-6989-4cfc-9a4b-ff501c57a596","owner":[],"postedDate":"October 1st, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2026-04-27T16:02:36+00:00","versionOfRecord":{"articleIdentity":"rs-7626916","link":"https://doi.org/10.1007/s00170-026-18016-6","journal":{"identity":"the-international-journal-of-advanced-manufacturing-technology","isVorOnly":false,"title":"The International Journal of Advanced Manufacturing Technology"},"publishedOn":"2026-04-20 15:57:32","publishedOnDateReadable":"April 20th, 2026"},"versionCreatedAt":"2025-10-01 09:02:34","video":"","vorDoi":"10.1007/s00170-026-18016-6","vorDoiUrl":"https://doi.org/10.1007/s00170-026-18016-6","workflowStages":[]},"version":"v1","identity":"rs-7626916","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7626916","identity":"rs-7626916","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}