Integrated Finite Element Modeling and High-Speed Impact Synthesis: A Novel Pathway for Embedded Al/W Energetic Composites

Propelled by accelerated technological innovation, the advancement of new material development has become imperative for emerging industries. The finite element method, leveraging multi-scale modeling and interdisciplinary integration, has established itself as one of the pivotal computational tools for significantly boosting research and development efficiency in material science. This study employed a combined approach of ABAQUS simulation and experimentation to efficiently design and synthesize an Al/W energetic composite characterized by concentrated energy release, high reaction enthalpy, and a unique discrete embedded structure. The finite element analysis focused on the stress distribution, equivalent strain, embedding depth, and energy conversion phenomena of heterogeneous particles under varying impact velocities. The results demonstrated that at a collision velocity of 500 m/s, embedded collisions between Al and W particles were achieved, providing effective guidance for synthesizing Al/W energetic composites with embedded structural features via high-speed impacts. TG-DSC analysis revealed that the Al/W energetic composites exhibited a reaction enthalpy change of 8806.0 ± 152 J/g and a maximum heat flow rate of 101.5 ± 2.8 W/g, which were 3.5-fold and 3.1-fold higher than those of pure Al with identical dimensions, respectively, and significantly surpassed the values of the mechanically mixed Al/W energetic composites. This integrated finite element simulation and experimentation provides a new pathway towards the efficient design and synthesis of novel materials with analogous components and structures.