Ti-16.5Zr-13.5Cu-8.5Ni (wt.%) as a filler and brazing process as 950 °C/60 min were supplied in this study for brazing cast TiAl alloys with fully lamella structure. The interface microstructure and element diffusion were analyzed and measured by SEM, EBSD, and EPAM. And the mechanical properties of joints were evaluated. The sound joints were achieved with strength as 575 MPa at room temperature and

A commercially available matrix phased array (MPA) ultrasonic imaging system was successfully integrated into a robot-assisted automated non-destructive testing (NDT) method for resistance spot weld applications. The NDT system utilizes a dual-time gate feature, where optimized time gate positions and widths were determined for near-normal incidence inspections of spot welds in thin materials. The

Advances in the dynamic response of welding power sources have allowed the use of pulsed current at frequencies above 20 kHz. However, the effects of pulsing the welding current at these high-frequency levels are not well known, especially those associated with the voltaic arc. Thus, the aim of this study was to carry out experimental research on a pulsating welding current at ultra-high frequencies

In this study, nickel-based alloy 625 and duplex stainless steel (DSS) UNS S32205 (2205) dissimilar pairs were welded with metal inert gas (MIG) welding process. Weld metal, obtained with the utilization of ERNiCrMo-3 filler wire, was subjected to mechanical, microstructural, and corrosion investigations. V-notch impact tests and micro hardness measurements were realized on dissimilar weld metal. Microstructural

Mg-Al-Zn (AZ31) of 10-mm thick plates were subjected to friction stir welding (FSW) using a conventional tool (CT) and bobbin tool (BT), respectively. The microstructure, room temperature tensile properties, dynamic compressive mechanical properties, and corrosion resistance of the base metal (BM) and various regions of the friction stir welded joints were investigated systematically. The mean grain

The effect of friction stir spot welding (FSSW) parameters on microstructure and mechanical properties of transformation-induced plasticity (TRIP) steel joints was investigated. The microstructure of the base metal and welding zone (stir zone, thermomechanically affected zone, and heat-affected zone) was examined using OM, SEM, EBSD, and XRD. The results of fractography of joints show that the microstructure

The material characteristics of high toughness and high strength in steel are usually not available at the same time. However, it would be an advantage if high-strength steels would show high impact toughness also at lower temperatures for applications in critical surroundings. In this paper, an approach of multi-layer welding of high-strength steel is presented in order to increase the weld-metal

For the purpose of high-temperature service potential and the weight reduction expectation in aviation engineering applications, dissimilar joining of TiAl alloy to Ni-based superalloy has been conducted with a newly designed Fe-based filler metal. The microstructure and chemical composition at the interfaces were investigated by SEM, EPMA, and XRD. The filler metal consisted of Fe-based solid solution

Carbide-free bainite (CFB) microstructures containing a mixture of nano-sized retained austenite laths and bainitic ferrite exhibit a good combination of strength, ductility, and toughness. In this work, an attempt was made to identify welding electrode compositions with a carbon content of about 0.35 to 0.5 wt.% to achieve carbide-free bainite microstructures in multi-pass shielded metal arc welds

Compared with conventional steels, press-hardened steels with an aluminium-silicon coating have a smaller welding range, which is resulting in reduced process stability. For this reason, an analytical methodology is required, which can optimise the welding parameters and extend the welding range significantly. Consequently, most publications focus on the variation of welding time and welding current

The influence of current pulse width on electrode wear during resistance spot welding of thin sheets (1 mm, 0.04 in) of aluminum alloy 6016-T4 was studied, and an increase in sheet surface roughness and electrode erosion was evident with increasing pulse time for the same weld nugget size. Aluminum alloy 6016-T4 is an especially critical material concerning electrode wear for resistance spot welding

In this paper, the utilization of gas-metal-arc-welding additive manufacturing (GMAWAM) for the repurposing of components was explored. Herein, the GMAWAM process was used to build new low-carbon steel features on an existing low-carbon steel component to obtain a new part with new functionalities. To confirm the internal quality of the new part obtained by such a strategy that is adequate for real

The improvement and optimization of post-weld treatments in the case of austenitic 316L stainless steels are, to a large extent, a condition of the service life of the associated structures. In this regard, mechanical brushing and heat treatment are post-weld techniques dedicated to the assembly of mechanically welded structures applicable in the aeronautics, food, and transport sectors. In this study

The influence of arc energy and filler metal composition on the microstructure of additively welded thin-walled structures of duplex stainless steels was investigated using different commercially available standard and superduplex solid wire electrodes commonly used today. As welding process, the cold metal transfer (CMT) process was used. The arc energy and cooling rate were varied by adjusting the

The aim of this work is to improve the fracture ductility of non-penetrating laser-welded lap joints. The 1.5 + 2.0 and 2.0 + 2.0 lap plates of cold-rolled 301LN stainless steel tilted 15° in the load direction and in the reverse load direction were welded by a vertical laser beam to prepare a positive-tilt weld (PTW) and negative-tilt weld (NTW). The tilt weld had a regular geometry, and the solidification

Residual stress and distortion of welded specimens are issues when it comes to geometrical requirements. The surrounding material prevents the dilatation associated with transformation in the area of heat input resulting in residual stress and distortion due to thermal contraction. In the past few years, low transformation temperature (LTT) material was successfully used as filler wire to reduce residual

The effect of high-frequency axial magnetic field (HFAMF) on the shape of the welding arc and welding formation of tungsten inert gas (TIG) welding is analyzed theoretically and experimentally. The 316L stainless steel plate was welded with HFAMF produced by the excitation coil installed on the welding torch. The influence of the HFAMF on the welding process is studied by changing the magnetic frequency

Traditional gas metal arc-based additive manufacturing (GMA-AM), also referred to as wire arc additive manufacture (WAAM), improves deposition rate via increasing deposition current, but it is easy to affect the shape-forming and microstructure of the deposited part due to the increased heat input. To avoid such problems, a novel auxiliary wire feeding GMA-AM (A-GMA-AM) approach is proposed to achieve

This research highlights the influence of bonding pressure on the features of diffusion-bonded joints (DBJs) between Ti6Al4V alloy and TiAlNb alloy investigated at 900 °C for 120 minutes in vacuum with variable pressures of 0.5, 1, 2, 3, and 4 MPa. Characterization of the bonded interfaces was conducted using optical microscopy and scanning electron microscopy in backscattered mode. A molecular dynamics

Advanced high-strength steel (AHSS) is a class of promising materials for safe and lightweight structural applications in the transportation industry due to its high energy absorption capacity during severe plastic deformation. However, some types of AHSS tend to become brittle after welding and fail during forming operations. This paper proposes a novel method of laser welding AHSS class of 22MnB5

Nitinol is a shape memory and superelastic alloy, respectively, and stainless steels are widely used materials in medical engineering, e.g., for implants and medical instruments. However, due to its high price and poor machinability, there is a high demand for dissimilar welding of nitinol components to stainless steel. During welding of titanium-containing alloys, like nitinol, to ferrous metals like

The aluminium alloy studied in this paper is the heat treatable AA7075 which has zinc as the main alloying element. 7xxx aluminium alloys have the best strength performance among all commercial series and AA7075 has tensile strength above 500 MPa. The outstanding strength properties open the possibility to use this alloy in automotive industry as a possible alternative material for car body elements

A three-dimensional CFD-model was developed to investigate Active-TIG welding of 304L-SS, involving heat transfer, fluid flow, solidification, plasma arc effect, Marangoni convections, magnetohydrodynamics and oxide particle trajectory. The aim was to understand how flux-induced particles are distributed in the weld line. The results, validated with available experimental data, showed that A-TIG forms

The galvanized steel with thickness of 2 mm was joined to 6061 with thickness of 2 mm by laser fusion-brazing process. The filler wire was AlSi5 and wire feed speeds were 2.8, 3.0, and 3.2 m/min, respectively. Microstructure and mechanical properties of the joints were investigated. The Zn-rich zone formed in the area of the seam toe was analyzed by means of optical microscope, scanning electron microscope

Fatigue evaluation based on the effective notch stress approach requires stress concentration factors for idealized notch geometries. In this paper, stress concentration factors are calculated numerically for different idealizations of the weld geometry. The joints covered here are one-sided Y-butt joints and two-sided DY-butt joints, each with partial and full penetration. The variable parameters

In this publication, the different metal transfer modes of a hot-wire GTAW process with indirect resistive preheating of the wire are presented. The hot-wire GTAW process is characterized by an additional preheating unit that is used to heat the wire before it reaches the melt pool. Thus, to preheat the wire, the contact between the melt pool and the wire is not necessary. In order to examine the metal

The study presents the results of tests of local static and cyclic properties of an explosively welded AA2519-AA1050-Ti6Al4V layered material. In order to perform the analysis, tests were carried out with the use of microspecimens collected from 10 layers of AA2519-AA1050-Ti6Al4V material. Additionally, the determined static properties were compared with the results of an analysis based on microhardness

The friction stir weld (FSW) method was developed in 1991 by The Welding Institute (TWI) and is very useful for manufacturing components with low fusion weldability. The success of this relatively new technique is due, in part, to an appropriate combination of some parameters. In order to understand the influence of the parameters such as rotation speed, axial force, and welding velocity, simulations

Lead-free “copper wire/Sn-3.0Ag-0.5Cu (SAC305) solder/copper wire” sandwich-structured micro-scale solder joints with a constant diameter (d = 400 μm) and various heights (125, 225, and 325 μm) were adopted to carried out the mechanical behavior research. Experimentally, quasi-static shear and tensile experiments were conducted by using a precision dynamic mechanics analyzer (DMA Q800). Then, the micro-scale

The brittle fracture driving forces of laser beam welds (LBWs) and arc welds (AWs) are investigated and compared numerically with a center through-thickness cracked panel (CTCP) and a standard fracture toughness specimen (3-point bending specimen, 3PB). The effects of hard zone width (H) and strength mismatch ratio (Sr) were systematically studied at global strain (ε∞) of 0.1% and 0.2%. It was found

This study aims to explore the mode of Zn transportation and the failure mechanism of cracking associated with liquid metal embrittlement (LME) using fractography as the key technique. A three-point bend test was performed on a TRIP steel resistance spot weld to open the LME crack in the form of a free fracture surface for the fractographic investigation. The presence of liquid Zn on the fracture surface

The growing demands on the quality of plastic components and the trend towards miniaturisation are posing a great challenge on plastics processing technology. As many complex components can no longer be manufactured in a single step, joining processes such as laser transmission welding are gaining in importance. In classic laser transmission welding, the joining partners have different optical properties

Due to different filling modes of the material in sleeve-affected zone (SAZ), probe-affected zone (PAZ), and thermo-mechanically affected zone (TMAZ), the micro-junction structure is formed at the bottom of the SAZ of the refill FSSW joint for 3.2-mm-thick 2060 aluminum alloys. The plasticized degree of the filling material and refilling time greatly affect the morphologies of micro-junction structure

Spatter generation is considered to be a practical problem in the industrial short-circuiting transfer process of gas metal arc welding. Extensive experimental research has been conducted, and some novel approaches have been developed to mitigate splatter generation. In this study, a three-dimensional numerical model of the short-circuiting transfer process was constructed, and the behavior of the

High-strength structural steels are used in machine, steel, and crane construction with yield strength up to 960 MPa. However, welding of these steels requires profound knowledge of three factors in terms of avoidance of hydrogen-assisted cracking (HAC): the interaction of microstructure, local stress/strain, and local hydrogen concentration. In addition to the three main factors, the used arc process

The paper is concerned with the problem of stress concentration in cruciform fillet welded joints subjected to axial and bending load. Extended numerical analyses were carried out with the help of the finite element method. It made it possible to estimate stress concentration factors Kt for a variety of geometrical parameters defining the geometry of cruciform welded joints. It has been found that

The main purpose of this work is to establish high cyclic fatigue behaviour of sound welds of aluminium alloys of Al-Mg-Li and Al-Cu-Li doping system under constant and variable amplitude loading. Sound welds of thin sheet (1.8 and 2.0 mm) aluminium-lithium alloys 1420 and 1460 were produced by tungsten inert gas (TIG) and friction stir welding (FSW) technologies. Microstructure investigations, hardness

Numerical investigation has been employed to analysis stress distribution in 9Cr/2.25Cr dissimilar welded rotor undergoing welding and heat treatment in order to help optimize structural design. The simulated residual stress on inner and outer cylindrical surface has been validated with experimental data. Distribution and evolution of welding residual stress along weld center line through thickness

Microstructure and mechanical properties of 6061-T6 aluminum alloy/304 stainless steel (Al/steel) joints welded by inertia friction (IFW) and continuous drive friction (CDFW) were studied comparatively. Morphology, microstructure, interfacial composition, and mechanical properties of Al/steel joints were investigated. Results showed that an intermetallic compound (IMC) reaction layer was formed at

Robustness of HFMI treatment in different weld qualities according to ISO 5817 was studied, and fatigue testing of the treated samples was carried out in order to investigate the effect of the weld quality prior treatment. The results show that HFMI-treated welds with weld quality level D shows fatigue life improvements that fall within the IIW recommendations for HFMI. No significant influence from

Arc-welding based additive manufacturing is a cost-efficient, productive technology which has been shown to be capable of producing high-integrity components. It is suggested that in automotive engineering, this manufacturing process can be used to reinforce body components by generating stiffening elements. Benefits of this method could be more flexural rigidity with comparatively lower material volume

During the cooling process of the molten material, residual stresses appear because the reduced volume of the cooled material cannot fully fill the space formerly occupied by the molten material. The morphology in and around the weld is formed by different factors depending on the material and process parameters. Different morphological structures relate to different mechanical properties. The process

Refrigerated ammonia storage tanks (RAST) are hazardous industrial facilities, where accidents with severe consequences occur. Defects of welded joints are one of the main reasons of RAST accident occurrence. Due to this, during the technical inspection, special attention is paid to quality control of welded joints. The use of non-destructive testing (NDT) for defect detection is essentially important

In the current study a method to determine the location of fracture initiation for non-load carrying fillet welds based on continuous geometry measurements is proposed. Measurements and weld quality evaluation were carried out on welded specimens using the Winteria® software qWeld. One hundred nineteen specimens were produced, scanned, and fatigue tested until failure. The fracture surfaces have been

In this study, brazing experiments were carried out on 6063 aluminum alloy using Al-20Cu-5Si-2Ni filler alloy. Microstructure, mechanical property, and removing behavior of oxide film of the brazed joints were analyzed. The results revealed that the 3% (CsF-AlF3) + 97% (KF-AlF3) non-corrosive flux showed high activity, especially effective removal of oxide films during the brazing process. For the

In this study, the residual stress simulations of the out-of-plane gusset welded joints examined by Leitner et al. (2016) in As-welded and HFMI-treated conditions which are performed by Ruiz (2018, 2019) are reviewed and verified. Based on the reviewed simulation’s results, the changes of residual stress under constant amplitude and compressive spike loads with various stress amplitudes are simulated

In order to produce three-dimensional components from metals, a wide variety of processes exist. Laser processes combined with metal powders are frequently used and developed. Restrictive factors are the machine-related small workspace, the machinery costs and the material portfolio, which place the technology in the area of high-performance components. Wire and arc additive manufacturing (WAAM), as

Graphite was successfully brazed to TZM alloy using the Ti-56Ni, Ti-8.5Si, Ti-33Cr and Ti-30V-3Mo brazing filler materials, respectively, and the corresponding brazing temperatures ranged from 1300 to 1700 °C. The results show that the microstructure of TZM/graphite braze metal was composed of NiTi and Ni3Ti compounds when using Ti-56Ni brazing filler, and the discontinuous TiC compounds were found

Stress distributions in the vicinity of type-b hot spot in the in-plane gusset welded joints and in the free edge of the stiffened cruciform welded joints were evaluated according to the solid model, the fine mesh shell model, and the coarse mesh shell model. The hot spot stress (HSS) of each FE model was evaluated by extrapolating the stresses at the read out point (ROP) to the hot spot position according

The electroslag welding process involves high heat inputs and high deposition rates. In this process, the weld region is surrounded by the base metal and/or devices; therefore, it is difficult to observe the phenomenon and understand the mechanism of weld formation. In this study, we directly observe the molten region formed during the process and construct a numerical model to discuss the phenomena

Conventional manufacturing processes for plastic products, such as injection molding or extrusion, often limit the achievable component geometries. Therefore, it is necessary to join components in order to generate highly complex geometries. Vibration welding is one way of joining components. This process is frequently used and is characterized by short cycle times, high energy efficiency, and the

For high-temperature joining of SiC ceramics, a multi-element AuPdCoMnNi alloy was designed and used as filler metal to join SiC ceramics to metal Mo. The brazing experiment was conducted under the condition of 1150 °C for 5 min and 10 min, respectively. The results show that numerous micro-cracks are visible in the directly brazed Mo/SiC joints, which are continuously distributed in bands of (Co,

An aluminium alloy (AA) cylinder measuring 145 mm diameter (∅) and 11 mm height was produced by wire and arc additive manufacturing (WAAM) using ER4043 filler wire and cold metal transfer (CMT) welding process. The macrostructure examination of the WAAM-processed cylinder revealed excellent bonding between the deposited layers without defects and exhibited superior structural integrity. The tensile

Martensitic stainless steels are deposited during manufacturing or repair to prolong the service life of a workpiece in a wide variety of industries such as steelmaking. The post-weld heat treatment (PWHT) is necessary to provide appropriate mechanical properties. In this research, a four-layer clad including a buffer and three layers of 13Cr-4Ni-1Mo stainless steel was deposited on AISI 4140 low-alloy

Spontaneous phase transformation in local areas of the austenitic microstructure to martensite with the release of carbides may appear during the manufacturing or operation of engineering products made of two-phase austenitic-martensitic steel grades. When inspecting the quality of products made of these steels, the problem of detecting the local zones of the martensitic phase and carbide precipitation

This paper aims to study the effects of different brazing temperatures and holding time on the exposing height of the brazing diamond and wetting angle of the solder, and to analyze the morphology and composition of the reaction products at the interface between the diamond and the solder. Using the Ni-Cr-B-Si composite solder, the orderly arrangement method, the flame spraying process, and the remelting

The relation between the voltage and the arc length in gas metal arc welding (GMAW) is an important characteristic. It determines the power transfer to a large extent, and its knowledge allows the control of the process. However, the voltage depends on a complex distribution of the electric conductivity along the current path and does not depend on the arc length only. A simplified electrical model

In the CO2 welding process, a consumable wire electrode is used and metal transfer phenomena are involved. However, when the arc current is high, the molten wire behavior becomes unstable, and it leads to a large degree of spattering. In this study, a three-dimensional unified model comprising both the arc plasma and the molten wire was constructed, and the behavior of them was visualized using numerical

Laser cleaning technology for pre-weld and post-weld treatments is a promising market due to its high efficiency and consistency, easy operation, and eco-friendly features. The weld quality influence of laser cleaning pre-treatment for the succeeding laser welding of the widely used industrial HSLA steel plates has been investigated in this work. The experimental results show that the laser cleaning

For lateral powder injection, adjustments of defocusing distance, powder feeding angle, and molten pool width are set as input variables, and the powder transport vector, powder outflow position vector, and the injection offset vector are determined. The powder transport model involving above adjustment parameters is constructed based on operation of such vectors, which have been verified in experiments