Residual stress and deformation in a welded joint will significantly reduce its service life, and thus the analysis and regulation of residual stresses are very important. In this paper, a SYSWELD software was used to numerically simulate the temperature field, residual stress field, and the welding deformation during welding with and without a Cu interlayer. Thermocouples were used to measure the

The latest advancements of MIG/MAG welding technologies have experienced a steep evolution in functionality, reliability, and ever-growing process and weld controllability, within widely interdisciplinary approaches and driven by demanding trends of Advanced Manufacturing (Industry 4.0). Technologic development can be optimized through basic research, which focuses on understanding the physical phenomena

This study deals with the fatigue strength of high-frequency mechanical impact (HFMI)-treated unprotected structural details made of mild steel S355 considering the influence of corrosive environmental conditions. The investigations are carried out on butt welded specimens with sheet thickness t = 15 mm and on transverse non-load-carrying attachment specimens with sheet thickness t = 25 mm. Two different

Microstructure evolution of friction stir processed 2507 duplex stainless steel was investigated at rotational speed of 400 rpm and traverse speed of 100 mm/min. The microstructural evolution in processed zone was studied by optical microscopy and electron backscattered diffraction. Regions in the stir zone and the thermo-mechanically affected zone experienced different microstructure evolution due

Dense continuous oxide layers of semi-solid Al6061 complicate joints; therefore, ultrasound is introduced to break the continuous oxide layer. In this study, stacked semi-solid Al6061 samples were compressed with the application of ultrasound at the semi-solid metal formation temperature. The distribution of oxide layer and the shear strength near the bonding surface were used to analyze the connection

This study consisted of a comparative evaluation of the mechanical properties and failure behavior of QP980 steel with those of DP980 steel spot welds. Moreover, this paper contributes to the existing knowledge of the resistance spot welding behavior of QP steels by analyzing their microstructure, hardness profile, tensile shear strength, cross tension strength, and failure behavior. It was found that

The aim of this work is to investigate the influence of ultrasonic vibration on the microstructure and texture evolution in ultrasonic-assisted friction stir welding (UaFSW) of AZ91 Mg alloy. Ultrasonic vibration with an amplitude of 15 µm induced to the weld line perpendicularly to the welding direction. A scanning electron microscopy equipped with electron backscattered diffraction (EBSD) was used

Vacuum brazing of GH3039 nickel-based alloy with Ni–P filler metal was conducted at different brazing temperature. The Ni–P filler metal with a thickness of 10.4 μm was prepared by electroless plating technique, and the lap joints of GH3039 alloy were obtained. The microstructures and phase compositions of GH3039/Ni–P/GH3039 joints under different brazing temperature were characterized by optical microscopy

Friction stir vibration brazing (FSVB) by application of mechanical vibration was introduced in this investigation. In the current research, the adjoining samples are vibrated normally to the brazing line while FSB is performed. Low carbon steel sheets are joined together using FSB and FSVB while SiC nanoparticles are also incorporated in the joint. The microstructure and mechanical behavior of the

Final product strength is dependent on material properties after processing, which can include secondary operations, such as ultrasonic welding. In this paper, it is shown that non-visible surface contamination can have a profound negative impact on the quality of an ultrasonic weld. Acrylonitrile–butadiene–styrene (ABS) was contaminated with commonly used chemicals in the polymer processing industry

Fatigue crack propagation (FCP) is the most threatening failure to welded joints due to high local stress concentration and the effect of welding residual stress (WRS). Therefore, fatigue life assessment of welded joints considering residual stress distribution is an important procedure in designing and maintaining of welded structures. In this study, fatigue life of welded structures is evaluated

A new dimensionless form of the solution to the problem of a Gaussian heat source in steady state on a semi-infinite solid is presented. Applying dimensional analysis, it is shown that dimensionless expressions of all characteristic values associated to an isotherm, as its maximum width or depth, are function only of the Rykalin number, Ry, and the dimensionless distribution parameter of the source

Herein, we theoretically and experimentally examined the effects of current pulse frequency on arc characteristics, weld appearance, and weld microstructure of AISI444 ferritic stainless steel (FSS) welded by tungsten inert gas (TIG). The arc shape, pressure, and density distribution of TIG welding were measured using a high-speed camera and the sensor measurement and keyhole probe methods. Moreover

The so-called hairpin winding technology, which is specially tailored to electrical traction components, deploys rectangular plug-in copper wires in the stator. The fusion welding of the adjacent wire ends is associated with challenges due to the high thermal conductivity as well as the porosity formation of the copper. During this study, the electron beam (EB) welding of electrolytic tough pitch (ETP)

This study aims to investigate influence of under- and over-treatment on residual stress state induced by HFMI numerically. Finite element simulations were performed using a flat plate model considering S355 where feed rate and the number of hits were varied. To reduce computational time, the mass scaling method was adopted to the simulations. In addition, in order to survey influence of surface removal

In the last decade, Additive Manufacturing (AM) technologies have been considered by both the automotive and aerospace industries for the production of end-use metallic parts, with a main focus on Powder Bed Fusion – Laser Beam / metallic (PBF-LB/M) technologies. However, AM parts present features that are deleterious to their cyclic properties. For a reliable design in terms of fatigue strength, existing

This research work was mainly concerned to investigate the effect of bonding temperature on the weldability of CoCrNi MEA with SUS 304 stainless steel. Shear test and nano hardness measurements were used to evaluate the mechanical performance of the welded joints. The formation of IMCs intensified along with the bond interface when samples were treated at low bonding temperature (i.e., 925 °C) which

The morphology evolutions of the sidebranch during the solidification of weld pool under transient conditions are investigated by experiments and a quantitative phase field (PF) method. The equations represent the transient conditions of the weld pool which are presented and coupled to the PF model. The sidebranching spacing obtained by the PF simulation agrees well with that obtained by the experimental

According to the periodical inspection manual for civil infrastructures in Japan, the visual inspection plays a very important role to detect deterioration such as fatigue cracking. Since the steel bridges are covered with paint coating, a fatigue crack is often detected as a crack of the paint. Conventionally, when a paint crack is detected, the paint coating is removed and magnetic particle test

In this study, a series of butt welding tests with oscillating fiber laser beams were performed on zinc-coated thin sheets of 0.8 and 1.2 mm thicknesses. The optimized welding parameters were used to produce robust welds with no perforations or pores. The weld formation process, microstructure, and mechanical properties of welded joints with the butt surfaces processed via laser and shear cutting techniques

In this study, the weldability of single-sided ultrasonic welding of 4-mm-thick carbon fiber/Nylon 66 composite was studied. Extensive welding was performed, and the weld microstructures, fractographies, and appearances of welded joints were examined and analyzed. It was found that the strengths of single-sided ultrasonic welded (SSUWed) joints made with proper welding variables are comparable to that

Friction stir welding (FSW) has developed into a reliable and increasing used industrial joining technology. Various tool configurations can be used for FSW, each of which has advantages and challenges. State-of-the-art FSW employs various tool configurations, including the conventional, the stationary shoulder, and the dual-rotational configuration which is characterized by separate control of shoulder

The current research aims in evaluating the 3D temperature distribution of the friction stir–welded plates of AA1100 alloy by using a 9-point finite difference method (FDM). The isotherms, surface plots, and temperature profiles have been obtained from the FDM to analyse the distribution of temperature and compare them with the experimental results. Microstructure analysis, residual stress distribution

The use of pulsed gas metal arc welding (P-GMAW) is fundamental to applications were versatility and control of heat input are required during deposition. However, when welding using pure argon shielding gas, a drawback is the instability derived from wandering of the cathode spots on the weld pool. This work investigates an alternative to weld steels using pure argon shielding gas with cold wire pulsed

Compound field–assisted laser cladding is an advanced laser processing technology. In this paper, the influence mechanism of single physical field parameters of electromagnetic-ultrasonic compound field–assisted laser cladding on the cladding layer as well as the parameter optimization of compound field–assisted laser cladding are investigated. The Box-Behnken design response surface methodology method

The increasing adoption of Open Science principles has been a prevalent topic in the welding science community over the last years. Providing access to welding knowledge in the form of complex and complete datasets in addition to peer-reviewed publications can be identified as an important step to promote knowledge exchange and cooperation. There exist previous efforts on building data models specifically

The original article has been corrected. The original article can be found online at https ://doi.org/10.1007/s40194-020-01046-3

The hot cracking susceptibility in the Trans-Varestraint test was evaluated using the nominal strain calculated using the curvature radius of a bending block and the thickness of a specimen based on the theory of material mechanics. The nominal strain was calculated using the material properties at room temperature. Thus, in the Trans-Varestraint test, the non-uniformity of the strain around the weld

Significant cost and time savings may be realised if multiple weld repairs are undertaken at the same location during the long-term maintenance of naval vessels. Consequently, this investigation simulates full-thickness hull welds, which are required to facilitate the removal and subsequent replacement of hull sections, by assessing the effects of 4 reoccurring weld repairs on a propriety quenched

High-energy density beam processes for welding, including laser beam welding and electron beam welding, are essential processes in many industries and provide unique characteristics that are not available with other processes used for welding. More recently, these high-energy density beams have been used to great advantage for additive manufacturing. This review of the literature serves to provide

This paper presents a numerical model of the laser welding of steel, taking into account the heat and mass flows, as well as thermal effects associated with phase transformations. It was assumed that the heat source is a laser with a symmetrical power distribution of the TEM10 beam in two welding condition variants: a stationary heat source and a source moving at a constant speed along the sample.

The laser-MAG hybrid welding in horizontal-vertical (PC) position was used to study the effect of different groove types on the quality of a root weld. Six combinations of bevel angles (50° + 0° (represents the groove angle of upper plate and lower plate respectively), 45° + 5°, 40° + 10°, 35° + 15°, 30° + 20°, and 25° + 25°) and root face sizes of 2 to 4 mm were designed. Hannover analyzer was used

This study aims to evaluate the weldability of dissimilar welds with the Inconel 625 and the Hastelloy C-276 nickel-based alloys deposited on ASTM A36 and AISI 1045 carbon steel plates. The welds were carried out by the GMAW process and evaluated by the Trans-Varestraint test. The test results were statistically evaluated, and Fusion Zone solidification processes were simulated in JMatPro software

In this paper, dissimilar joining of NbSS/Nb5Si3 composites to GH5188 Co-based superalloy was performed by using two commercial Ni-based brazing filler alloys, BNi-2 and BNi-5 fillers. The interfacial microstructures of the brazed joints were investigated by scanning electron microscope equipped with an X-ray energy dispersive spectrometer. Three-point bending test was also conducted. When brazed with

The microstructure and mechanical properties of an API 5CT L80 casing grade steel (0.24C 0,4Si 1.4Mn CrNiCu) have been studied after performing weld thermal simulations (with and without subsequent tempering) applying a thermal cycle weld simulator. Specimens were subjected to three different peak temperatures (1300 °C, 1150 °C, 950 °C) and five different cooling rates (1 °C/s, 3 °C/s, 5 °C/s, 10 °C/s

Active vision sensing is widely used in intelligent robotic welding for bead detection and tracking. Disturbed by welding noise such as arc light and spatter, it is a hard work to extract the laser stripe and feature values. This paper presents a method for denoising and feature extraction of weld seam profiles with strong welding noise in gas metal arc welding (GMAW) process by using stacked denoising

In the meantime, it’s well known that post-weld fatigue strength improvement techniques for welded structures like high-frequency mechanical impact (HFMI) treatment increase the fatigue live of welded joints. Although the current design recommendations for HFMI-treated welded joints give first design proposals for the HFMI-treated welds, in practice the application of HFMI treatment and the associated

The joining of the SiCf/SiBCN composite was difficult due to the undue reactions between the SiCf/SiBCN composite and the common Ni- or Co-based filler alloy. In this paper, a new filler alloy with the nominal composition of Co-20Ni-12Pd-18Nb-15Cr (wt.%) was newly designed to join the SiCf/SiBCN composite. Compared with the BNi-5 filler alloy, the periodic banded structure in the reaction layer was

A numerical scrutiny was performed to analyze the effect of driving forces on molten pool in gas metal arc welding. In addition to the basic governing equations required for a general heat and mass transfer analysis by computational fluid dynamics, a volume-of-fluid equation for free surface tracking and additional conservation equations for calculating the distribution of alloy elements were used

The formations and fracture behavior of the AA2A14-T6 aluminum alloy friction stir welded (FSWed) joints are investigated under different ratios of rotational speed to welding speed (n/v). The relationship between the viscous layer (δ) and the rheological layer (ξ) is the key factor to determine the welding quality of joints. When δ < ξ, loose microstructure, needle-like, dispersive, or through void

Friction stir welding (FSW) is a relatively new welding technology. Although FSW technology has been widely used in many industries, there is a lack of effective online detection method of process parameters. Weld temperature and tool positioning are two key parameters in the study of process parameters. To realize online measurement of weld temperature and tool positioning in FSW, a measurement method

Friction stir welding (FSW) is a solid-phase welding method. Weld forming and welding quality are related to the heat generated by plastic flow in FSW process. Therefore, it is of great significance to realize the measurement of the viscoplastic heat generated in FSW process. In this paper, based on the working principle of rotary viscometer, the calculation model for the viscoplastic heat in friction

Dissimilar metal welds (DMWs) made between ferritic steels and austenitic alloys are used extensively in high-temperature power plant components. These DMWs experience premature creep failure in the ferritic steel’s heat affected zone (HAZ), close to the weld interface. Steep variations in microstructure and chemical composition across the dissimilar weld interface have been the contributing factors

The optimization of welding parameters of the welded joints of TC4 titanium alloys/304 stainless steel (TC4/304 SS) by friction stir lap welding (FSLW) based on orthogonal test was researched. The results show that under low heat input (low rotating speed and high traversing speed), there was a damaging defect in stir zone (SZ) and cracks started from the defect under the tension. Under high heat input

Transient liquid phase (TLP) bonding of Ti-6Al-4V/IN718 dissimilar joint was investigated using Cu interlayer at 950 °C for 5–45 min. The microstructure of the bonding zone was studied by using optical and scanning electron microscopes, energy dispersive spectroscopy, and X-ray diffraction analysis. Shear and microhardness tests were also used to evaluate the mechanical properties of the TLP joints

The morphology of the weld seam, the formation mechanism of interface, and the microstructure and mechanical properties of both direct and AlSi12 (ER4047)-added dissimilar 5A06Al/Ti6Al4V lap joints were investigated, respectively. The Gibbs free energies of intermetallic compounds, such as TiAl3, TiAl, and Ti3Al, were calculated. The results showed that the interface layers were mainly composed of

Carbon steels can be sensitive to solidification cracking. Predicting their susceptibility to solidification cracking can save cost and time compared to testing, and it can be very useful for designing new steels or welds. Crack susceptibility predictions were made for carbon steels using the recently proposed simple susceptibility index for cracking during solidification, maximum │dT/d(fS)1/2│ near

The joining of thick-walled components using beam-based joining techniques is content of worldwide research and development activities, but has not yet been established in industry. State of the art to weld nickel super alloys is currently a TIG narrow-gap welding. The present paper is focusing on a new specific laser beam welding process, the so-called Laser Multi-Pass Narrow-Gap welding (Laser-MPNG)

Single-step joining of dissimilar material combinations between ultra-high-strength steels and high-strength aluminium alloys with sufficient mechanical joint properties by using conventional resistance spot welding equipment has not been reported yet. In this research paper, a novel single-step joining technology, so-called self-penetrating resistance element welding, is introduced. First, the motivation

In this study, we develop a 3D transient mathematic model to simulate the heat transfer, fluid flow, and geometry morphology in GMAW-based wire arc additive manufacturing (WAAM). The processes of droplet formation, growth, and detachment from the end of wire electrode, who travels dynamically along the scanning direction, are coupled with molten pool for the first time by considering their own mechanical

High-entropy alloys (HEAs) and compositionally complex alloys (CCAs) represent new classes of materials containing five or more alloying elements (concentration of each element ranging from 5 to 35 at. %). In the present study, HEAs are defined as single-phase solid solutions; CCAs contain at least two phases. The alloy concept of HEAs/CCAs is fundamentally different from most conventional alloys and

MARBN alloys, which are anticipated an estimated 25 °C increase in advanced ultra-super critical (A-USC) power plant operating temperature, are expected to be commercially available soon and will partially displace some older materials and lead the market. Two examples are the Japanese alloy, 9Cr-3W-3Co-Nd-B material, which is considered a strong contender in wrought pipework, and the UK’s IBN-1 alloy

The purpose of this paper is to present the extension of a previously developed strain-based fracture mechanics (SBFM) model from one to two dimensions for simulating fatigue crack growth in steel arc welds. The one-dimensional (1D) SBFM model is first briefly reviewed. Steps for extending it to simulate 2D growth of a semi-elliptical surface crack in a weld are then described. An application of the

ISO 12135, which provides a fracture toughness test procedure, requires crack front straightness. In order to meet this requirement in weld specimens, Annex C to ISO 15653 provides a local compression (LC) technique. Although this technique has been used widely, some interested parties have reported that it often results in excessive underestimation of the critical CTOD. Following these previous studies

The influence of arc energy and different filler metal composition on the mechanical properties and macro- and microstructure of additively welded thin-walled structures of Ni-based alloy were investigated using four different variants commercially available solid wire electrodes of type S Ni 6625. As the welding process, the Cold Metal Transfer (CMT) process was used. The heat input and cooling rate

Ultrasonic vibration-assisted plasma arc welding with controlled pulse current waveform was developed to weld the 8 mm thick stainless steel plates. Both bead-on-plate and butt welding experiments were carried out with open-loop and closed-loop control strategies under different welding conditions. The signals of welding current and efflux plasma voltage and the images of keyhole exit were sensed to

That increasing temperature is beneficial for solder-wetting but not for amorphous-maintaining the state causes difficulties in joining of Zr-based bulk metallic glass (BMG). In order to solve the contradiction, this paper presents a two-step process of pre-cladding ultrasonic soldering, in which a Zn-6Al-3Cu-20Sn solder layer was firstly vacuum-cladded on surface of a Ti-6Al-4V sample, and then a

Powder bed fusion (PBF) is an additive manufacturing (AM) technique commonly used to manufacture metallic components. External geometry of parts printed by PBF process can be extended by regular processes, namely, laser cladding and spraying powder metal. But these methods have disadvantages such as increased heat-affected zone (HAZ) and extended deficiencies like cracks and pores, whereas samples

A copper-based (Cu-40Ag-6Ga-1Si, wt.%) filler metal was developed and used for Ti-6Al-4V brazing. The solidus temperature of the filler metal is 773.05 °C and the liquidus temperature is 776.14 °C. The spreading coefficient and contact angle of the filler metal at 850 °C on TC4 are 95.07% and 5°, respectively. The brazing experiment of Ti-6Al-4V (TC4) was performed using the copper-based filler metal

The empirical equation to predict the heat-affected zone (HAZ) hardness of B-added steels has been proposed. For this purpose, weld thermal cycle simulation tests of both B-free and B-added steels in combination with hardness measurements were conducted. Firstly the previous HAZ hardness prediction equation was modified using the experimental results of B-free steels. Next, by introducing the B effect