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The purpose of this study, which is designed for the implementation of models in the implicit finite element framework, is to propose a robust, stable and efficient explicit integration algorithm for rate-independent elasto-plastic constitutive models.

The proposed automatic substepping algorithm is founded on an explicit integration scheme. The estimation of the maximal subincrement size is based on the stability analysis.

In contrast to other explicit substepping schemes, the algorithm is self-correcting by definition and generates no cumulative drift. Although the integration proceeds with maximal possible subincrements, high level of accuracy is attained. Algorithmic tangent stiffness is calculated in explicit form and optionally no analytical second-order derivatives are needed.

The algorithm is convenient for elasto-plastic constitutive models, described with an algebraic constraint and a set of differential equations. This covers a large family of materials in the field of metal plasticity, damage mechanics, etc. However, it cannot be directly used for a general material model, because the presented algorithm is convenient for solving a set of equations of a particular type.

The estimation of the maximal stable subincrement size is computationally cheap. All expressions in the algorithm are in explicit form, thus the implementation is simple and straightforward. The overall performance of the approach (i.e. accuracy, time consumption) is fully comparable with a default (built-in) ABAQUS/Standard algorithm.

The estimated maximal subincrement size enables the algorithm to be stable by definition. Subincrements are much larger than those in conventional substepping algorithms. No error control, error correction or local iterations are required even in the case of large increments.

To present numerical approaches to the solution of physically coupled non‐linear problems, which frequently happen to be characterized by their multi‐domain character.

By adopting coupled solution strategies a considerable attention is devoted, in order to obtain a computationally efficient numerical algorithm, to the selection of appropriate space and time discretization, as well as to a proper discrete approximation method used.

Coupling of two methods, the finite element method and the boundary element method, respectively, has proved to be computationally exceedingly advantageous, particularly in case of moving domains.

As specific case studies computer simulation of an induction heating problem and a mushy‐state forming problem are considered. A thorough discussion on the coupling effects, characterizing the evolutions of respective physical quantities' fields, is given, and their impact on those evolutions is identified.

This paper presents efficient numerical strategies for the solution of a certain class of multi‐physics and multi‐domain problems.