B. B. Sherpa

This study explores the feasibility of explosive welding to join dissimilar materials: aluminum (JIS A1050‐H24) and two cast iron types (JIS G 5501 and JIS G 5502), which are challenging to weld due to the presence of graphite in the cast iron. Further, the impact of explosive thickness (28, 38, and 47 mm) on weld quality is investigated, considering microstructure and mechanical behavior. Increasing explosive thickness correlates with a thicker local melted zone. Remarkably, in investigations, a novel morphology that diverges from conventional patterns is observed. The weld interface of explosively bonded materials exhibits anchor formation, a unique interlocking structure. These anchors play a significant role in establishing a robust mechanism between bonded surfaces. JIS A1050‐H24 shows minimal hardness variation, while cast iron exhibits significant variations with increased explosive thickness. Tensile shear tests showcase robust clad plate strength, with fractures primarily in JIS A1050‐H24 regions instead of at the interface. The highest tensile shear strength is achieved with an explosive thickness of 38 mm. Overall, explosive welding of aluminum with cast iron creates a strong, durable, and lightweight material with enhanced performance characteristics, making it promising for diverse industrial applications due to its outstanding properties.