Numerical Modeling and Experimental Characterization of the Mechanical Impact on a Dissimilar Structured Steel by GMAW
Abstract
1. Introduction
2. Materials and Methods
2.1. Materials
2.2. Layer Deposition
2.3. Charpy Impact Tests
2.4. Impact FEM Simulation
| Material | Parameters | |||||
|---|---|---|---|---|---|---|
[Pa] | [Pa] | [Pa] | ||||
| MARS 500 (Q&T) | 1.22 × 109 | 31.9 × 103 | 6.32 | 0.32 | 7.51 × 109 | 200 × 109 |
| MARS 500 (annealed) | 310 × 106 | 40.0 | 5.0 | 0.3 | 763 × 106 | 200 × 109 |
| 309L | 325 × 106 | 0.3 | 10.0 | 0.5 | 701 × 106 | 210 × 109 |
| DO*15 | 1.50 × 109 | 100.0 | 2.84 | 0.0 | 6 × 103 | 200 × 109 |
3. Results and Discussions
3.1. Charpy Impact Test
3.2. Metallurgical and Mechanical Characteristics of the DSS


3.3. Charpy Impact Test Results of DSS
3.4. Charpy Impact Simulation Results
4. Conclusions
- The microstructure analysis demonstrated full fusion of the welded layers between the dissimilar metallic alloys, MARS 500 Q&T, 309L ASS, and DO*15 HF; thus, a DSS was successfully manufactured. Also, it showed a microstructural transformation from martensite to ferrite of the MARS 500, due to the welding heat input.
- The DSS presented a good mechanical behavior in structural impact applications, because it supported impact forces larger than the corresponding ones supported by monolithic 309L ASS and DO*15 HF samples. Also, the DSS absorbed up to 10% more impact energy than the MARS 500 Q&T.
- The 3D scanning of the fractured DSS Charpy samples was employed to measure the length of the fracture path and correlated it to the force–time curve. This information provided the average fracture propagation rate through each material layer of the sample. The use of this correlation method presents a novel approach used in this research.
- The convergence analysis indicated that the usage of an element size of 0.13 mm at the notch region was sufficient to obtain adequate results from the finite element simulation. These numerical results showed close agreement with the experimental values.
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
Abbreviations
| ASS | Austenitic stainless steel |
| ASTM | American Society for Testing and Materials |
| FEM | Finite element method |
| GMAW | Gas metal arc welding |
| HAZ | Heat-affected zone |
| HF | Hardfacing |
| HIC | Hydrogen induced cracking |
| Q&T | Quenched and Tempered |
| SEQV | Stress equivalent |
| List of Abbreviations | |
| Force | |
| Mass of the striker | |
| Yield stress | |
| Initial yield stress | |
| Liters | |
| Ampere | |
| Voltage | |
| Impact velocity | |
| s | Striker displacement |
| Cowper–Symonds strain hardening parameter | |
| Cowper–Symonds strain rate parameter | |
| Strain rate | |
| Effective plastic strain | |
| Young’s modulus | |
| Plastic hardening modulus | |
| Tangent elastic modulus | |
| Time | |
References
- Barbosa, V.S.; de Godois, L.A.; Bianchi, K.E.; Ruggieri, C. Charpy impact energy correlation with fracture toughness for low alloy structural steel welds. Theor. Appl. Fract. Mech. 2021, 113, 102934. [Google Scholar] [CrossRef]
- ASTM E23-24; Standard Test Methods for Notched Bar Impact Testing of Metallic Materials. ASTM: West Conshohocken, PA, USA, 2024.
- ISO 148-1; Metallic Materials—Charpy Pendulum Impact Test. Part 1: Test Method. ISO: Geneva, Switzerland, 2016; p. 12.
- Ambriz, R.; Jaramillo, D.; García, C.; Curiel, F. Fracture energy evaluation on 7075-T651 aluminum alloy welds determined by instrumented impact pendulum. Trans. Nonferrous Met. Soc. China 2016, 26, 974–983. [Google Scholar] [CrossRef]
- Chaouadi, R.; Gérard, R. Development of a method for extracting fracture toughness from instrumented Charpy impact tests in the ductile and transition regimes. Theor. Appl. Fract. Mech. 2021, 115, 103080. [Google Scholar] [CrossRef]
- Cabrilo, A.; Sedmak, A.; Burzic, Z.; Perkovic, S. Fracture mechanics and fatigue crack propagation in armor steel welds. In Engineering Failure Analysis; Elsevier: Amsterdam, The Netherlands, 2019; Volume 106. [Google Scholar]
- Godzimirski, J.; Komorek, Z.; Komorek, A. An Energy Analysis of Impact Strength Tests Using Pendulum Hammers. Adv. Sci. Technol. Res. J. 2019, 13, 214–222. [Google Scholar] [CrossRef]
- Acar, D.; Canpolat, B.H.; Cora, Ö.N. Ballistic performances of Ramor 500, Armox Advance and Hardox 450 steels under monolithic, double-layered, and perforated conditions. Eng. Sci. Technol. Int. J. 2024, 51, 101653. [Google Scholar] [CrossRef]
- Atapek, S.H. Development of a New Armor Steel and its Ballistic Performance. Def. Sci. J. 2013, 63, 271–277. [Google Scholar] [CrossRef]
- Balakrishnan, M.; Balasubramanian, V.; Reddy, G.M. Microstructural Analysis on Ballistic Tested Armour Steel Joints Fabricated Using Low Hydrogen Ferritic Consumables for Capping Pass. Key Eng. Mater. 2019, 812, 1–8. [Google Scholar] [CrossRef]
- Kim, J.-S.; Yi, H.-J. Characteristics of GMAW Narrow Gap Welding on the Armor Steel of Combat Vehicles. Appl. Sci. 2017, 7, 658. [Google Scholar] [CrossRef]
- Magudeeswaran, G.; Balasubramanian, V.; Reddy, G.M. Metallurgical characteristics of armour steel welded joints used for combat vehicle construction. Def. Technol. 2018, 14, 590–606. [Google Scholar] [CrossRef]
- Kah, P.; Pirinen, M.; Suoranta, R.; Martikainen, J. Welding of Ultra High Strength Steels. Adv. Mater. Res. 2014, 849, 357–365. [Google Scholar] [CrossRef]
- KılıÇ, N.; Ekici, B.; Hartomacıoğlu, S. Determination of penetration depth at high velocity impact using finite element method and artificial neural network tools. Def. Technol. 2015, 11, 110–122. [Google Scholar] [CrossRef]
- Saxena, A.; Kumaraswamy, A.; Dwivedi, S.P.; Srivastava, A.K.; Maurya, N.K. Experimental and computational investigation on dynamic fracture toughness (J1d) behavior of multi-pass SMA armor steel weldments. Theor. Appl. Fract. Mech. 2020, 106, 102502. [Google Scholar] [CrossRef]
- Xin, H.; Veljkovic, M. Evaluation of high strength steels fracture based on uniaxial stress-strain curves. Eng. Fail. Anal. 2021, 120, 105025. [Google Scholar] [CrossRef]
- Gangwar, V.; Acharyya, S.; Banerjee, A. Calibration of tensile tests in drop-weight impact machine and implementation in simulation of Charpy impact tests. Procedia Struct. Integr. 2024, 60, 123–135. [Google Scholar] [CrossRef]
- Yang, Q.; Wang, Y.; Li, D.; Liu, R.; Wang, C.; Zhao, J. Research on charpy impact test and simulation of laser welded joints in 6252 armor steel. Theor. Appl. Fract. Mech. 2025, 138, 104920. [Google Scholar] [CrossRef]
- Seo, K.-W.; Kim, J.-Y.; Kim, Y.-J.; Kim, K.-S. Finite Element Ductile Fracture Simulation of Charpy and Drop Weight Tear Tests for API X52. Theor. Appl. Fract. Mech. 2024, 133, 104629. [Google Scholar] [CrossRef]
- Wong, W.J.; Walters, C.L. Damage mechanics model for correlating notch toughness in Charpy impact tests with fracture toughness in cracked static fracture tests. Eng. Fract. Mech. 2025, 320, 111043. [Google Scholar] [CrossRef]
- Gangwar, V.; Basu, P.; Acharyya, S.; Dhar, S.; Chakraborty, S.; Banerjee, A. Dynamic deformation and fracture surface investigation of rolled homogenous armor steel through Charpy impact testing. Theor. Appl. Fract. Mech. 2024, 133, 104592. [Google Scholar] [CrossRef]
- Kim, H.; Park, J.; Kang, M.; Lee, S. Interpretation of Charpy impact energy characteristics by microstructural evolution of dynamically compressed specimens in three tempered martensitic steels. Mater. Sci. Eng. A 2016, 649, 57–67. [Google Scholar] [CrossRef]
- Rosenberger, J.; Tlatlik, J.; Rump, N.; Münstermann, S. Prediction of statistical force–displacement curves of Charpy-V impact tests based on unsupervised fracture surface machine learning. Eng. Fail. Anal. 2025, 175, 109551. [Google Scholar] [CrossRef]
- Tria, D.; Trębiński, R. Methodology for experimental verification of steel armour impact modelling. Int. J. Impact Eng. 2017, 100, 102–116. [Google Scholar] [CrossRef]
- Sagar, C.K.; Chilukuri, A.; Priyadrashini, A. Determination of Johnson Cook Material Model Constants for 93% WHA and Optimization using Genetic Algorithm. Mater. Today Proc. 2018, 5, 18911–18919. [Google Scholar] [CrossRef]
- Baroth, J.; Malecot, Y.; Boukria, Z.; Briffaut, M.; Daudeville, L. Prediction of the perforation of targets impacted by deformable projectiles. Int. J. Impact Eng. 2015, 80, 36–44. [Google Scholar] [CrossRef]
- Andreotti, R.; Casaroli, A.; Colamartino, I.; Quercia, M.; Boniardi, M.V.; Berto, F. Ballistic Impacts with Bullet Splash—Load History Estimation for .308 Bullets vs. Hard Steel Targets. Materials 2023, 16, 3990. [Google Scholar] [CrossRef] [PubMed]
- Babaei, B.; Shokrieh, M.M.; Daneshjou, K. The ballistic resistance of multi-layered targets impacted by rigid projectiles. Mater. Sci. Eng. A 2011, 530, 208–217. [Google Scholar] [CrossRef]
- Holmen, J.K.; Solberg, J.K.; Hopperstad, O.S.; Børvik, T. Ballistic impact of layered and case-hardened steel plates. Int. J. Impact Eng. 2017, 110, 4–14. [Google Scholar] [CrossRef]
- Zhang, Q.; Yuan, Y.; Zhang, C.; Zhang, Y.; Chen, P. Enhancing the ballistic resistance of steel/aluminum bilayer armor plates through explosive welding. Mater. Des. 2023, 234, 112346. [Google Scholar] [CrossRef]
- Savic, B.; Cabrilo, A. Effect of Heat Input on the Ballistic Performance of Armor Steel Weldments. Materials 2021, 14, 3617. [Google Scholar] [CrossRef]
- Lincoln Electric. BLUE MAX MIG 309L. 2025. Available online: https://www.lincolnelectric.com/es-mx/products/bluemaxmig309lsi_gmaw (accessed on 14 October 2025).
- AWS A5.9/A5.9M; Specification for Bare Stainless Steel Welding Electrodes and Rods. American Welding Society: Miami, FL, USA, 2012.
- Eutectic Castolin. EnDOtec DO*15 Flux-Cored Wire Ø 1.6mm. 2026. Available online: https://shop.castolin.com/en-si/endotec-do-15-flux-cored-wire-1521?srsltid=AfmBOooH4AVu-_Ok3AIPyyBKPkLsaUtpqKtYqjSz1UR9pJ5GVl0Od4is (accessed on 14 October 2025).
- EN 14700; Welding Consumables—Welding Consumables for Hard-Facing. Danish Standards Association: Nordhavn, Denmark, 2005.
- Mars 500 High Hardness Armor. May 2026. Available online: https://industeel.arcelormittal.com/wp-content/uploads/2026/03/DS-PROTECTION-MARS-500-EN-26.pdf (accessed on 1 May 2026).
- Cortés-Rodríguez, R.; López-Morelos, V.H.; Ambriz, R.R.; Cortés-Carrillo, E.; Sanchez Cruz, T.d.N.; Curiel-López, F.F. Sliding wear behavior of AISI 1045 carbon steel plates weld overlay with EnDOTec DO15 using CMT. Surf. Coat. Technol. 2025, 517, 132803. [Google Scholar] [CrossRef]
- ASTM E8/E8M-22; Standard Test Methods for Tension Testing of Metallic Materials. ASTM: West Conshohocken, PA, USA, 2022.
- Joseph, P.; Babu, M.N.; Albert, S.K. Fracture Behavior of Hardfacing Alloy Coated Over Stainless Steel under Quasi-Static and Dynamic Loads. J. Mater. Eng. Perform. 2024, 33, 13019–13029. [Google Scholar] [CrossRef]
- Seetharamu, S.J.T.; Malagi, R.R. Fatigue, Durability, and Fracture Mechanics; Lecture Notes in Mechanical Engineering (LNME); Springer: Berlin/Heidelberg, Germany, 2019. [Google Scholar]
- Hernandez, C.; Maranon, A.; Ashcroft, I.; Casas-Rodriguez, J. A computational determination of the Cowper–Symonds parameters from a single Taylor test. Appl. Math. Model. 2013, 37, 4698–4708. [Google Scholar] [CrossRef]
- Frutos, J.; Ambriz, R.; García, C.J.; Jaramillo, D. Orthogonal impact load in 6061-T651 and 7075-T651 aluminum alloy plates. J. Mater. Res. Technol. 2023, 26, 4245–4262. [Google Scholar] [CrossRef]
- Ansys. Ansys, Guidelines for Mesh Convergence in Ansys Mechanical. 2023. Available online: https://innovationspace.ansys.com/courses/courses/topics-in-meshing-for-structural-analysis/lessons/guidelines-for-mesh-convergence-in-ansys-mechanical/ (accessed on 14 October 2025).
- Myers, R.H.; Montgomery, D.C.; Anderson-Cook, C.M. Response Surface Methodology: Process and Product Optimization Using Designed Experiments, 4th ed.; Wiley: Hoboken, NJ, USA, 2016. [Google Scholar]
- Škrlec, A.; Klemenc, J. Estimating the Strain-Rate-Dependent Parameters of the Cowper-Symonds and Johnson-Cook Material Models using Taguchi Arrays. J. Mech. Eng. 2016, 62, 220–230. [Google Scholar] [CrossRef]
- Škrlec, A.; Panić, B.; Nagode, M.; Klemenc, J. Estimating the Cowper–Symonds Parameters for High-Strength Steel Using DIC Combined with Integral Measures of Deviation. Metals 2024, 14, 992. [Google Scholar] [CrossRef]
- Škrlec, A.; Klemenc, J. Parameter identification for a Cowper-Symonds material model using a genetic algorithm combined with a response surface. Eng. Comput. 2017, 34, 921–940. [Google Scholar] [CrossRef]
- Zhao, Q.; Xiao, X.; Ge, R.; Zhang, Y.; Chen, X.; Jia, B. Experimental-numerical study on ballistic impact behavior of 316L austenitic stainless steel plates against blunt and ogival projectiles. Int. J. Hydrogen Energy 2023, 48, 8526–8548. [Google Scholar] [CrossRef]
- Kou, S. Welding Metallurgy; John Wiley & Sons, Inc.: Hoboken, NJ, USA, 2003. [Google Scholar]
- Zhao, X.; Ren, K.; Lu, X.; He, F.; Jiang, Y. Study on fusion boundary microstructure and mechanical properties of austenitic stainless steel-nickel based dissimilar alloy materials welded joints. Eng. Fract. Mech. 2023, 281, 109140. [Google Scholar] [CrossRef]
- Wang, W.; Wang, J.; Wang, Q.; Huang, X.; Lu, G.; Liu, Y.; Liu, C. Ferrite-austenite synergistic deformation behavior in a 2205 duplex stainless steel containing equiaxed austenite domains. Mater. Charact. 2023, 205, 113363. [Google Scholar] [CrossRef]











| Material | Ni | Cr | Mo | V | Mn | W | C | Si | S | P | Fe |
|---|---|---|---|---|---|---|---|---|---|---|---|
| MARS 500 | 1.8 | 1 | 0.6 | - | 1.0 | - | 0.31 | 0.5 | 0.002 | 0.010 | Bal |
| 309L | 13.4 | 23.3 | 0.04 | - | 1.8 | - | 0.01 | 0.8 | 0.02 | 0.02 | Bal |
| DO*15 | - | 4.12 | 1.48 | 0.36 | 0.81 | 1.84 | 0.36 | 0.79 | - | 0.02 | Bal |
| Filler Material | 309L ASS | DO*15 HF |
|---|---|---|
| Diameter | 0.9 mm | 1.6 mm |
| Shielding gas | Ar 100% | Ar 100% |
| Wire feed | 8.7 m⋅min−1 | 5.2 m⋅min−1 |
| Volumetric deposition rate | 92.2 mm3⋅s−1 | 174.3 mm3⋅s−1 |
| Gas flow | 20 L⋅min−1 | 20 L⋅min−1 |
| Voltage | 21.1 V | 20.0 V |
| Current | 126 A | 150 A |
| Specific energy on the wire | 28.8 J⋅mm−3 | 17.2 J⋅mm−3 |
| Stick out | 10 mm | 10 mm |
| Welding torch travel speed | 0.3 m⋅min−1 | 0.8 m⋅min−1 |
Disclaimer/Publisher’s Note: The statements, opinions and data contained in all publications are solely those of the individual author(s) and contributor(s) and not of MDPI and/or the editor(s). MDPI and/or the editor(s) disclaim responsibility for any injury to people or property resulting from any ideas, methods, instructions or products referred to in the content. |
© 2026 by the authors. Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license.
Share and Cite
Chávez Carrillo, R.; Jaramillo, D.; Mendoza, C.; Ambriz, R.R. Numerical Modeling and Experimental Characterization of the Mechanical Impact on a Dissimilar Structured Steel by GMAW. Processes 2026, 14, 1938. https://doi.org/10.3390/pr14121938
Chávez Carrillo R, Jaramillo D, Mendoza C, Ambriz RR. Numerical Modeling and Experimental Characterization of the Mechanical Impact on a Dissimilar Structured Steel by GMAW. Processes. 2026; 14(12):1938. https://doi.org/10.3390/pr14121938
Chicago/Turabian StyleChávez Carrillo, Ramsés, David Jaramillo, César Mendoza, and Ricardo Rafael Ambriz. 2026. "Numerical Modeling and Experimental Characterization of the Mechanical Impact on a Dissimilar Structured Steel by GMAW" Processes 14, no. 12: 1938. https://doi.org/10.3390/pr14121938
APA StyleChávez Carrillo, R., Jaramillo, D., Mendoza, C., & Ambriz, R. R. (2026). Numerical Modeling and Experimental Characterization of the Mechanical Impact on a Dissimilar Structured Steel by GMAW. Processes, 14(12), 1938. https://doi.org/10.3390/pr14121938

