A welding window is one of the key concepts used to select optimal regimes for high-velocity impact welding. In a number of recent studies, the method of smoothed particle hydrodynamics (SPH) was used to find the welding window. In this paper, an attempt is made to compare the results of SPH simulation and classical approaches to find the boundaries of a welding window. The experimental data on the welding of 6061-T6 alloy obtained by Wittman were used to verify the simulation results. Numerical simulation of high-velocity impact accompanied by deformation and heating was carried out by the SPH method in Ansys Autodyn software. To analyze the cooling process, the heat equation was solved using the finite difference method. Numerical simulation reproduced most of the explosion welding phenomena, in particular, the formation of waves, vortices, and jets. The left, right, and lower boundaries found using numerical simulations were in good agreement with those found using Wittman’s and Deribas’s approaches. At the same time, significant differences were found in the position of the upper limit. The results of this study improve understanding of the mechanism of joint formation during high-velocity impact welding.

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In this study, the process of high-velocity impact welding of commercially pure Al and Ti plates was simulated using smoothed particle hydrodynamics (SPH) method. The paper aimed to determine by numerical simulation the range of collision parameters suitable for Al and Ti welding, and to compare the results obtained with the known semi-empirical models used to construct the "weldability window". For this, a set of simulations with different collision point velocity and collision angle was carried out. From the data obtained, it follows that SPH simulation reproduces well the shape of the interface, typical for high-velocity impact welding, and provides better understanding of material flow and related phenomena. This method allows one to select the collision parameters that are optimal for a high-quality joint.