Wyniki wyszukiwania - BazTech

1

Dissimilar ti alloys welding for the automotive and aviation sector

Węgrzyn Tomasz, Szczucka-Lasota Bożena

Zeszyty Naukowe. Transport / Politechnika Śląska

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2025

|

z. 129

283--291

EN

Titanium alloys have an excellent strength-to-weight ratio. Tit alloys are almost as strong as steel but are much lighter. This translates into reduced mass in means of transportation (e.g., aircraft, F1 cars, electric vehicles, and motorcycles), which translates into better fuel efficiency, speed. Titanium can withstand very high temperatures without losing its mechanical properties. As a result, it has found applications in exhaust systems, hydraulic lines, fuel systems, and structural elements exposed to extreme conditions. In the construction of means of transport, two types of titanium with different structures are mainly used (alpha titanium and alpha + beta titanium). There will certainly soon be a need to weld these two dissimilar materials together. This is a research gap. An absolute novelty is the attempt to weld dissimilar titanium alloys without using a protective vacuum chamber. The purpose of this article is to establish the correct parameters for this process.

2

Economic aspects of of titanium alloy Ti-5Al-2.5Sn welding for aviation applications

Węgrzyn Tomasz, Szczucka-Lasota Bożena, Jurek Adam, Piotrowicz Paweł, Labus Artur, Lasota Patrycja

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

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2025

|

z. 221

639--645

EN

Purpose: Novelty of the paper is to present the Ti alloy welding for aeronautic application. Welding titanium is treated as a difficultprocedure. The aim of the article is to develop the TIG (Tungstan Inert Gas) welding process for titanium alloys instead of much more expensive process of welding in vacuum chamber Design/methodology/approach: Main parameters of the titanium alloy welding process were tested and then the quality of the obtained joint was checked by the mechanical tests. Findings: Welding parameters were determined without carring out the process in vacuum chamber that is much more expensive and energy-intensive process. Research limitations/implications: It was suggested to investigate the effect of modified shielding gas mixtures (Ar-He) for the TIG process. Practical implications: The proposed process innovation will result in savings of production cost, because titanium alloys are mainly welded in a vacuum chamber, which is more expensive process. Social implications: Vacuum chamber in the welding process allows for energy savings. Originality/value: It is to propose a new solution in aeronautic industry. The article is especially addressed to manufacturers of titanium alloys for aviation.

3

Super Duplex - AHSS welding for electric vehicles

Szczucka-Lasota Bożena, Węgrzyn Tomasz, Kamińska Joanna, Pereira Silva Abilio, Łazarz Bogusław

Transport Problems

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2025

|

T. 20, z. 1

59--71

EN

Solutions for planning and improving transport processes often require the modification of existing transport equipment or the development of new equipment to increase its operational range or improve its efficiency. Appropriately introduced modifications contribute to maintaining the smooth flow of the process, enabling transport in a wider operational range. Proprietary solutions consisting of increasing the operational range of the extension arm by incorporating high-strength steels into their structure made it possible to extend the arms of these devices while maintaining the total weight of the device and appropriate high-performance parameters. The solution allows operators to reach places previously inaccessible to these devices, thus eliminating the need to use other devices in the logistics process. An important element of the solution is to ensure the passive safety of the structure; hence, the solution created for the needs of transport logistics required the development of an appropriate process for joining different types of steel. This type of joint is important in the automotive industry, especially in the construction of mobile platforms, because, on the one hand, a light, spacious, and durable structure is required, and on the other hand, this structure should be characterized by good anti-corrosion properties. The uniqueness of the presented solution is evidenced by the fact that the developed processes supporting the reduction of the “carbon footprint” were deliberately used to combine elements of two different types of steel: super duplex (SD) steel and advanced high-strength steel (AHSS), which is a technological novelty in combining the discussed steel grades. The CO2-free gas mixture was selected for technological and environmental reasons in accordance with EU directives, which strongly recommend reducing CO2 emissions in the automotive industry. The purpose of this article is to present a solution for the execution of welded joints, high- strength steels with duplex steels, ensuring the achievement of the desired structures of transport equipment, taking into account the principles of sustainable development and striving in this area to reduce CO2 in technological processes. The main methods for checking the quality of the welded dissimilar joint were based on the tensile, bending, and impact toughness tests. The results are very promising, and the obtained correct joints are characterized by high mechanical properties suitable for constructing mobile platforms in the automotive industry. The presented solution supports activities for sustainable development and logistics in transport. The proposed solution to modify transport means will improve the functionality of this device. The solution was developed to address the need to implement the transport processes of the examined organization.

4

Spawanie – proces technologiczny o szczególnych wymogach

Józefiak Marta

Promotor BHP

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2025

|

nr 7-8

16--18

PL

Spawanie jest zaliczane do prac szczególnie niebezpiecznych. Na co należy zwrócić uwagę, aby wykonywana praca była zgodna z obowiązującymi przepisami?

5

Dissimilar Hardox and low-alloy steel in excavator structures

Szczucka-Lasota Bożena, Węgrzyn Tomasz

Zeszyty Naukowe. Transport / Politechnika Śląska

|

2024

|

z. 124

217--227

EN

In the structure of excavators and other transport vehicles, it is observed that there is an increasing necessity to weld elements from the Hardox steels. The paper verifies the possibility to obtain accurate DMW (dissimilar metal welds from totally different grades of Hardox 450 steel with S355J2 steel). The microstructure and mechanical tests of the obtained various welds were analysed. Argon-based shielding gases with micro nitrogen additions were used for MAG welding. Gas mixtures with micro nitrogen additions of up to even 2000 ppm and their use in welding are an absolute novelty. The purpose of the manuscript was to find the correct parameters of making dissimilar joints with such modern mixtures and to determine the most suitable mixture for welding Hardox steel and low-alloy steel for use in the automotive industry.

6

DOCOL 1100M welding in the construction of electric means of transport

Szczucka-Lasota Bożena, Gołombek Klaudiusz, Węgrzyn Tomasz, Łazarz Bogusław, Lukaszkowicz Krzysztof, Pereira Silva Abilio, Antczak-Jarząbska Romana

Transport Problems

|

2024

|

T. 19, z. 2

219--228

EN

Advanced high-strength steels are important for the automotive sector. Metal active gas (MAG) is the most popular method for joining grades of steel. The goal of the paper is to analyze the mechanical properties of the MAG welding joint made of high-strength DOCOL 1100M intended for the construction of electric vehicles. The manuscript shows a basic understanding of the properties of DOCOL joints. This type of material is characterized by a martensitic microstructure, which makes it difficult to make a proper joint. The tensile strength, metallographic structure, and type of non-metallic inclusions were analyzed as a function of the oxygen amount in the protective gas mixture. Investigations of oxide non-metallic inclusions were carried out using scanning electron microscopy. This article attempts to obtain high joint strength of the electric vehicle structure by controlling the average size of non-metallic inclusions in the weld, which is influenced by shielding gas in the MAG welding process. The solution has application potential for the automotive industry, especially for electric vehicles.

7

A micro-cooled high-strength weld for heavy transport means

Węgrzyn Tomasz, Szczucka-Lasota Bożena, Szymczak Tadeusz, Łazarz Bogusław, Piwnik Jan

Transport Problems

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2024

|

T. 19, z. 1

83--96

EN

This paper focuses on the technical problem of repairing the main operating elements of heavy vehicles (semitrailers, dumps, and drums). If these vehicles are in service, significant changes in work schedules can occur, and costs can be generated immediately. Therefore, using the correct technology for repairs is crucial to minimizing financial and logistic difficulties. The article aims to analyze the mechanical properties of an MMA (Manual Metal Arc) welding (covered electrodes) joint made of Hardox 450 steel. This kind of material has a martensitic microstructure, which is difficult to weld because of changes in the components to the other ones during the joint process. Other inconveniences are related to the different chemical composition of steel and covered electrodes, their mechanical resistance, and thermodynamic conditions (consisting of the pre-heating temperature and the cross-pass temperature). Therefore, the joint quality should be determined using a few methods. In this case, NDT (magnetic and radiographic tests) and DT (microstructural analysis and static as well as fatigue tests) were used. All obtained results have enabled the proposed guides for the MMA welding of the steel grade. This is indicated as follows: (1) the method of bevelling the sheets before welding should be used, (2) pre-heating is necessary at temperature levels of 100 C and 125 C, and (3) the recommended interstitial temperature is between 170 C and 200°C.

8

Research on welding processes of multi-node aircraft frames and methods for their control

Bałon Paweł, Rejman Edward, Kiełbasa Bartłomiej, Smusz Robert, Szeliga Grzegorz

Mechanik

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2024

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R. 97, nr 5-6

54--59

EN

The designed aircraft frame structure uses a connection of tubular rods by welding. To apply automatic welding of trusses, the authors designed and assembled the welding station adapted to the dimensions and truss shape. You should also choose the appropriate welding power source and an interface for communication with a robot or automaton. Automatic welding of trusses also requires programming of the robot’s movement trajectory, especially the welding head, and a particularly accurate selection of welding process parameters. The most important issue of automation of the welding process is the nodes of the aircraft engine frame, whose limited access requires manual welding. Therefore, the future of welding lattice aircraft structures requires a hybrid approach to the process, i.e. some of the node connections can be easily automated, and some will remain in classical manufacturing methods. In addition, the topic of checking such connections using NDT methods was discussed. In addition, the issue of checking this type of connection using methods approved for aviation, i.e. NDT, was discussed.

PL

W projektowanej konstrukcji ramy samolotu zastosowano połączenie prętów rurowych poprzez spawanie. Aby zastosować spawanie automatyczne kratownic, autorzy zaprojektowali i zmontowali stanowisko spawalnicze dostosowane do wymiarów i kształtu kratownicy. Należy również dobrać odpowiednie źródło zasilania spawania i interfejs do komunikacji z robotem lub automatem. Spawanie automatyczne kratownic wymaga programowania trajektorii ruchu robota, zwłaszcza głowicy spawającej, oraz bardzo dokładnego doboru parametrów procesu. Najistotniejszą kwestią automatyzacji procesu jest spawanie węzłów ramy silnika samolotu, które ze względu na ograniczony dostęp wymagają spawania ręcznego. Zatem przyszłość spawania kratowych konstrukcji lotniczych wymaga hybrydowego podejścia do procesu - czyli częściowo proces łączenia węzłów można będzie prosto zautomatyzować, a częściowo trzeba będzie pozostać przy klasycznych metodach wytwarzania. Ponadto podjęto tematykę kontroli tego typu połączeń metodami dopuszczonymi dla lotnictwa, tj. NDT.

9

Welding of lifting equipment structures made of steel DOCOL 1300 M

Węgrzyn Tomasz, Szczucka-Lasota Bożena, Jurek Adam, Jurek Piotr

Materials Science and Welding Technologies / Technologie Materiałowe i Spawalnicze

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2024

|

Vol. 68, No. 5

art. no. 6

EN

Because of their high temporary tensile strength and significant fatigue strength, DOCOL steels from the AHSS group (AHSS – Advanced High-Strength Steel) are often used in the fabrication of mobile platforms. The welding of the above-named steels is difficult due to the dominant martensitic structure and requires extensive experience. The article discusses the identification and adjustment of welding parameters appropriate for steel DOCOL 1300M and presents the assessment of the effect of selected process parameters, i.e. filler metal wires, shielding gas mixture and, primarily, the correct preheating temperature, on the quality of welded joints.

PL

W budowie podestów ruchomych coraz częściej wykorzystuje się stale DOCOL z grupy AHSS (AHSS – Advanced High-Strength Steel), z uwagi na ich wysoką, doraźną wytrzymałość na rozciąganie i znaczną wytrzymałość zmęczeniową. Spawanie tych stali jest utrudnione, ze względu na dominującą strukturę martenzytyczną. Podczas spawania tych stali szczególną rolę odgrywa doświadczenie. W artykule opisano dobór właściwych parametrów spawania stali DOCOL 1300 M i przedstawiono ocenę wpływu wybranych parametrów procesu, takich jak: dobór drutu elektrodowego, osłonowej mieszanki gazowej, a przede wszystkim ustalenie prawidłowej temperatury podgrzewania wstępnego na poprawność wykonanego złącza.

10

Gas pipeline welding procedure qualification – standards and tests

Silezin Julia, Parzych Sławomir

Materials Science and Welding Technologies / Technologie Materiałowe i Spawalnicze

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2024

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Vol. 68, No. 3

art. no. 3

EN

The article describes the so-called combined welding technologies, marked as method “A” – 141/135, method “B” – 141/111 and method “C” – 141/136. In each of the methods, the root run (root layer) was obtained using method 141, whereas the groove was filled using methods 135, 111 and 136. In respect of the welding technology qualification process, the key issue was connected with finding an appropriate range of values for a heat input to each run, aimed to prevent dangerously high grain growth in the HAZ. The results of welded joint tests were fully consistent with the PN-EN ISO 15614-1 and PN-EN 12732 standards as well as Annex 5 to PI-ID-I03.

PL

W artykule opisano tzw. kombinowane technologie spawania, które oznaczono jako: metoda „A” − 141/135, metoda „B” − 141/111, metoda „C” − 141/136. W każdej z metod warstwę przetopową wykonano metodą 141, a wypełnienie rowka metodą kolejno: 135, 111, 136. W kontekście procesu kwalifikowania technologii spawania, kluczowe było znalezienie odpowiedniego przedziału wartości ilości wprowadzonego ciepła spawania każdego ze ściegów, aby wskutek kumulacji ciepła spawania uniknąć niebezpiecznie wysokiego rozrostu ziarna w SWC. Otrzymane wyniki badań złączy spawanych są zgodne z wymaganiami norm PN-EN ISO 15614-1 oraz PN-EN 12732, a także załącznika nr 5 do PI-ID-I03.

11

Electron beam welding of high-strength aluminium alloys

Śliwiński Piotr, Węglowski Marek St., Kubik Kamil, Gotkowski Piotr

Materials Science and Welding Technologies / Technologie Materiałowe i Spawalnicze

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2024

|

Vol. 68, No. 2

art. no. 5

EN

Owing to the greater precision of energy density control, the highest possible metallurgical purity of the process and the lack of sensitivity to reflectivity and surface roughness, electron beam welding is a suitable method for joining aluminium alloys. The paper presents results concerning the welding of aluminium alloy grades 6060 and 6061 as well as experimental alloys having higher copper contents. The tests discussed in the paper led to the obtainment of joints characterised by a high strength of up to 289.7 MPa and the lack of unacceptable imperfections.

PL

Spawanie wiązką elektronów, ze względu na większą precyzję kontroli gęstości energii, najwyższą możliwą czystość metalurgiczną procesu oraz brak wrażliwości na współczynnik odbicia światła i chropowatość powierzchni, jest odpowiednią metodą łączenia stopów aluminium. W niniejszym artykule przedstawiono wyniki spawania stopów aluminium w gatunku: 6060, 6061, a także eksperymentalnych stopów o podwyższonej zawartości miedzi. W ramach badań uzyskano złącza charakteryzujące się wysoką wytrzymałością, nawet do 289,7 MPa, a także brakiem niedopuszczalnych niezgodności.

12

Popożarowe zmiany strukturalne w złączach spawanych stali niestopowych

Klimek Marcin, Pańcikiewicz Krzysztof

Inżynieria i Budownictwo

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2024

|

R. 80, nr 3

128--132

PL

W artykule poruszono zagadnienie wpływu pożaru na zmiany w strukturze i właściwościach mechanicznych złączy spawanych elementów ze stali niestopowych. Analizie poddano procesy zachodzące podczas spawania, mające wpływ na uzyskiwaną wejściową strukturę i właściwości w spoinie i strefie wpływu ciepła. Na tej bazie dokonano zwięzłej analizy wpływu niskotemperaturowego i wysokotemperaturowego pożaru oraz sposobu jego gaszenia na zmiany w strukturze i właściwościach mechanicznych złączy spawanych stali niestopowych. Zarekomendowano prowadzenie ekspertyz popożarowych stalowych konstrukcji spawanych.

EN

In the article deals with the issue of the impact of fire on changes in the structure and mechanical properties of welded joints of non-alloy steel elements. The processes occurring during welding, affecting the obtained input structure and properties in the weld and in the heat affected zone, were analyzed. On this basis, a concise analysis of the impact of low- and high-temperature fire and the method of extinguishing it on changes in the structure and mechanical properties of welded joints of non-alloyed steels was made. Recommendations for conducting post-fire expertise of welded steel structures are included.

13

Process parameters influence the mechanical properties and nugget diameter of AISI 316 stainless steel during resistance spot welding

Hamzah Mahmood Mohammed, Barrak Osamah Sabah, Abdullah Isam Tareq, Hussein Aws Abdulillah, Hussein Sabah Khammass

International Journal of Applied Mechanics and Engineering

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2024

|

Vol. 29, no. 2

79--89

EN

Resistance spot welding (RSW) is an important fusion welding process used in many applications, including storage tanks, pipes, and medical tools. For this, should be improved the joints and developing the process parameters and through this research will be discussed the results and concept development. Herein, 1 mm-thick AISI 316 austenitic stainless steel was welded by RSW, and the effect of the welding process parameters, such as “welding current, pulses, squeeze time, and welding time”, on the mechanical properties, nugget diameter (ND), and microstructure of AISI 316 were investigated. As a result, there was a direct relationship between shear-tensile force and ND. The maximum shear-tensile force (12.5 kN) was obtained using 7500 A, 3 pulses, 1.8 s squeeze time, and 1 s welding time. The ND was maximized using 7500 A, 3 pulses, 1.6 s squeeze time, and 0.8 s welding time. The DOE analysis gives an indication about the relation between the parameters and ND on the hand and the parameters and shear strength on the other hand. The microstructure was investigated by optical microscopy, revealing the presence of martensitic, widmanstatten austenite, and ferrite structures.

14

Technologia śledzenia spoiny

Dozór Techniczny

|

2024

|

z. 2

s. 27--27

PL

Firma Cloos wprowadza nową technologię śledzenia spoiny z wykorzystaniem sensora prądowego dedykowaną dla cobota QINEO ArcBoT.

15

Inteligentne systemy wspomagające spawanie zrobotyzowane

Dozór Techniczny

|

2024

|

z. 6

20--21

PL

WireSense, TouchSense, SeamTracking i sprawdzony w praktyce TeachMode to opatentowane systemy wspomagające spawanie zrobotyzowane, opracowane przez firmę Fronius.

16

Energooszczędne spawanie TIG

Dozór Techniczny

|

2024

|

z. 2

s. 17--17

PL

Nowy urządzenie do spawania metodą TIG – Fronius Artis sprawdzi się przy spawaniu stali nierdzewnej, w takich zastosowaniach jak poręcze czy baseny, gdzie liczy się estetyka każdej spoiny. Równie dobrze sprawdza się w tworzeniu wysokiej klasy połączeń rur oraz w precyzyjnych zastosowaniach, takich jak budowa zbiorników i instalacji przemysłowych. W przypadku nowej serii źródeł energii TIG położono nacisk przede wszystkim na przyjazność dla użytkownika, niezawodność i energooszczędność - przy czym warto zaznaczyć, że Artis ma na wyposażeniu wszystkie funkcje jego poprzednika, czyli systemu Fonius TransTig.

17

Czy coboty zainteresują młode pokolenie spawaniem?

Dozór Techniczny

|

2024

|

z. 6

15--19

PL

Spawanie pozostaje głównym procesem spajania w branży obróbki metalu, ale wymaga gruntownej wiedzy i zręczności. Mimo dobrego wynagrodzenia ubywa młodych ludzi decydujących się na ten zawód, ponieważ jest on często postrzegany jako nieatrakcyjny, szkodliwy dla zdrowia i brudny. Odpowiedzią na te argumenty mogą być coboty. Sprawiają, że spawanie staje się nie tylko ciekawsze i bezpieczniejsze, ale także bardziej rentowne – nawet przy małych seriach.

18

Study of microstructure and mechanical properties of high thickness A844/A516 steel joints by multi-pass GMAW for pressure vessels

Zhang Hongwei, Wang Yinwei, Dang Bo

Archives of Civil and Mechanical Engineering

|

2024

|

Vol. 24, no. 3

art. no. e185, 2024

EN

In this study, the gas metal arc welding (GMAW) process was investigated for similar and dissimilar joints of A844 and A516 steel plates in different thicknesses. For welding, E 19-10H filler metal and category D joint design were used for joining nozzles to the cargo tank body. Also, the dependence of the microstructure, strength, and impact energy (cryogenic fracture toughness) on the cooling rate (∂T/∂t) was evaluated. Due to the effect of the square of thickness on the heat transfer rate, with the increase in thickness (8–10 mm), the cooling rate (∂T/∂t) increased by 57% for similar joints. According to this increase, the strength and cryogenic fracture toughness for the similar joints of A844 steel plates increased by 8 and 9%, respectively. For similar joints of A516 steel plates, it increased by 6 and 9%, respectively. The strength and cryogenic fracture toughness of dissimilar joints with different thicknesses depended on the type of base metals and the different cooling rates of each base metal. Continuous plastic deformation was observed in the weld zone during bending tests because E19-10H filler metal has more than 30% elongation. Also, the presence of any kind of cracks in the joints was ruled out by performing radiographic tests.

19

Friction welding of UFG copper using the W2Mi prototype machine

Morawiński Łukasz, Jasiński Cezary, Goliński Jacek, Chmielewski Tomasz M.

Archives of Civil and Mechanical Engineering

|

2024

|

Vol. 24, no. 3

art. no. e139, 2024

EN

When welding ultra-fine-grained metals using conventional methods, the microstructure in the joint area is degraded (mainly due to recrystallization) in the heat-affected zone and a significant deterioration of mechanical properties, including joint strength. The aim of the research presented in this article was to identify the possibility of obtaining joints with strength close to initial material using friction welding of metal materials with ultra-fine grain. For this purpose, UFG (ultra-fine-grained) material was produced from technically pure M1Ez4 copper using a hybrid SPD (severe plastic deformation) process. The welding process was carried out on a machine with a prototype design that allows minimizing the welding time, while generating high force. The process parameters used on the prototype machine resulted in an increase in the hardness of the material by 4% in the joint area. The strength of the joint compared to the base material decreased slightly by 2%. The tests carried out proved that, using appropriate process parameters, it is possible to obtain a UFG metal joint without a decrease in its mechanical strength.

20

Capabilities and limitations of the simplified smoothed particle hydrodynamics explosive welding model

Mojżeszko Mateusz, Madej Łukasz

Archives of Civil and Mechanical Engineering

|

2024

|

Vol. 24, no. 1

art. no. e37, 2024

EN

The process of explosive welding offers very attractive capabilities of joining dissimilar materials, but at the same time, it is a highly intricate and advanced technology involving a multitude of phenomena occurring in the colliding plates in a matter of microseconds. In this case, numerical modeling can greatly support understanding local material behavior and eventually designing the welding technology for the particular investigated metals. Therefore, this work aims to create a robust numerical model that will reflect the main mechanisms controlling the explosive welding process, consider the properties of the bonded materials, and provide results in a short time. To reflect the complexity of this process, the meshless calculation method SPH (smooth particle hydrodynamics) was used. However, before the computer-aided technology design stage, the explosive welding model has to be thoroughly investigated to eliminate any unphysical artifact that can affect the interpretation of the final results. Therefore, in the current research, the simplified model was proposed to confirm the method's robustness and show its capabilities along with the limitations in capturing the required physics. The key aspects of the model, e.g., the role of computational domain discretization, capabilities to reflect the influence of collision angle on material behavior or local temperature increase leading to melting, were investigated. With this work, we have clearly demonstrated the high capabilities of the SPH method in simulation explosive welding complexity even with the simplified 2D model. At the same time, the importance of particular model development stages was highlighted to provide clear guidelines for researchers working in this field.