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Mg alloys are extensively used in various automotive, aerospace, and industrial applications. Their limited corrosion resistance can be enhanced by welding a thin Al plate onto the alloy surface. In this study, we perform the explosive welding of a thin Al plate, accelerated by the detonation of an explosive through a gelatin layer as a pressure-transmitting medium, onto two Mg alloy samples: Mg96Zn2Y2 alloy containing a long-period stacking ordered phase in an α-Mg matrix and commercial AZ31. The bonding interface is characterized using optical microscopy, scanning electron microscopy, X-ray diffraction, and electron probe microanalysis. Under moderate experimental conditions, the thin Al plates are successfully welded onto the Mg alloys, showing typical wavy interfaces without intermediate layers. Due to the decreased energetic condition corresponding to the use of a thin flyer plate and gelatin medium, the resulting bonding quality is better than that obtained using a regular explosive welding technique. Further, based on the well-known window for explosive welding, we estimate that the experimental conditions for successful bonding are close to the lower welding limit for a thin Al plate with the two Mg alloys considered. These findings may contribute to improving the quality of materials welded with explosive welding.

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In this work, interlayers with different thickness were used to weld A6061 aluminum alloy and SUS 821L1 duplex stainless steel. The results indicated that the interlayer thickness had a significant effect on the welding. The influence of the air shock wave between the plates on the welding results was examined. The fluid-Solid coupling finite element method was used to simulate the movement of the interlayer under the action of the air shock wave. The smoothed particle hydrodynamics method was used to simulate the oblique impact process of the plates, and the unwelded samples were analyzed using the simulation results. In the analysis of weldability window, the influence of the interlayer on the upper and lower limits was examined.

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