In the automotive industry, it is essential to reduce the weight of the car body to improve fuel efficiency and reduce CO2 gas emissions. As such, the application of advanced high-strength steels is rapidly increasing. However, in the case of gas metal arc (GMA) welding of advanced high-strength steels (AHSS), slag particles are observed to form on the weld surface resulting in poor corrosion resistance

Stainless steel has been widely used in the manufacture of metro car-body because of superior characteristics. But the traditional welding joints are prone to poor properties. Ultra-narrow gap laser welding (UNGLW) with low heat input can address property issues. However, due to the complicated parameter interaction in UNGLW, it is difficult to acquire the welding joint with excellent comprehensive

Joining technology of metal and dissimilar materials is attracting attention in various industrial fields. Especially in the automotive industry, the joining of metal and plastics is expected to be a key technology for weight reduction. A new joining technology of metal to plastics has been developed by laser surface pretreatment to metal. The pretreatment is done by a continuous wave (cw) single mode

The present paper aims to characterize the welding residual stresses, microstructure, and mechanical properties of some AISI 410 plates welded with low-transformation temperature (LTT) fillers containing different Ni wt.%. The LTT fillers with 11 wt.% Cr and Ni content varying between 3 and 11 wt.% were produced using an arc melting furnace. Effect of Ni wt.% on Ms of LTT fillers was studied using

Due to their mechanical and corrosive properties, nickel-based alloys are very important in several industrial sectors like power stations, chemical apparatus, and the oil industry. While flux-cored arc welding (FCAW) of carbon steels often uses flux-cored wires (FCW), the use of Ni-based flux-cored wires is industrially less common. The reasons for this include the lower degree of recognition and

AHSS is widely used in the automobile industry due to its lightweight and high strength. However, the larger carbon equivalent results in poor weldability and causes a severe performance decrease in the performance of the CGHAZ. The thermal simulation was utilized to analyze the fracture mechanism of the CGHAZ of DP780 high-strength steel, and the microstructure and mechanical properties of the CGHAZ

In many cases, flame straightening is unavoidable after welding for the reduction of deformation. Due to the not very concentrated heat source, the process can cause significant changes in the microstructure, especially in high strength and wear-resistant steels. Due to their different physical properties, the effects vary depending on the flammable gases (acetylene, propane). The situation is complicated

7xxx series aluminum alloys are susceptible to solidification cracking during fusion welding. This study systematically investigates the solidification cracking susceptibility of T-Mg32(AlZn)49-strengthened Cu-free Al-Mg-Zn alloy with a Zn/Mg ratio below 1.0. The alloy is different from η-MgZn2-strengthened 7xxx series alloys whose Zn/Mg ratios are above 1.0. The crack length of the studied Al-Mg-Zn

To improve automotive fuel economy, automobile manufacturers are minimizing the weight of the body-in-white. To do this, they are adopting new 3rd generation advanced high strength steels that have excellent strength and ductility. However, these steels are also prone to liquid metal embrittlement (LME) cracking; intergranular cracks caused by molten zinc, from the galvanized coating, penetrating the

The effects of activating fluxes on weld bead morphology, arc behavior, electrical signals, and temperature field were investigated. Real-time weld pool dynamics, electrical signal waveforms, and temperature contours were obtained by high speed camera, real-time electric signal acquisition card, and infrared thermal camera. The additions of SiO2, TiO2, ZnO, and Fe2O3 not only improved the weld formation

SAF 2205 and IN X-750 were joined using the TLP method. The joining process was carried out at 1100 °C for different times using BNi-3 interlayer. Microstructural study and identification of the present phases in the bonding regions were performed using optical microscopy and scanning electron microscopy equipped with energy-dispersive X-ray spectroscopy and electron backscatter diffraction technique

Additive manufacturing enables the fabrication of lattice structures which are of particular interest to fabricate medical implants and lightweight aerospace parts. Product integrity is critical in these applications. This requests very challenging quality control for such complex geometries, particularly on detecting internal defects. It is important not only to detect whether there are missing struts

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This paper presents a new two-pass friction stir welding (FSW) implementation called parallel friction stir welding (P-FSW). This process is classified into two categories: Advanced parallel friction stir welding (AP-FSW) and retreating parallel friction stir welding (RP-FSW). The effects of three parameters named the type of process, tool offset in first pass, and tool offset in the second pass on

Grain morphology and texture of welds significantly affect the properties of the corresponding joint. It is very important to determine how heat and grain growth during welding correlate. Our studies involved both experiments and multi-scale numerical modeling. The laser welding temperature distribution was studied by the macroscopic finite element method. The grain growth and morphology evolution

In many cases, both laser and electron beam welding may be considered for critical applications involving a wide range of structural materials. The ability to use both processes to make comparable welds in terms of both weld profile (penetration) and microstructure provides considerable process selection flexibility. In this study, autogenous, partial penetration welds on 304 and 304L SS were made

A Ni-based superalloy, Inconel 625, is widely used for aerospace, petrochemical and marine applications due to its excellent corrosion and elevated temperature mechanical properties. In this study, efforts were made to identify optimum deposition parameters to produce directionally solidified Inconel 625 components using wire arc additive manufacturing (WAAM). Components were deposited by short-circuiting

The effects of rotation speed and plunge depth on macro/microstructures and mechanical properties of dissimilar 2195/2219 aluminum alloy joints produced by refill friction stir spot welding (RFSSW) were investigated. The results show that some shallow annular grooves present on the joint surfaces depending on the process parameters. Besides, hook defects are in the form of downward bending due to the

Cf/SiC composites were joined to itself with (and without) Mo interlayer at 1150 °C for 10 min by Cu–Pd–V filler metal. For two kinds of the joints, after the interfacial reactions, continuous V–C layers and dispersive V–C particles were formed at surface of the joined Cf/SiC composite. It was worth noting that much more dispersive particles were formed in case of Cf/SiC–Mo–Cf/SiC joint which was favorable

In this study, the traditional α–β titanium alloy Ti6Al4V sheets were joined by the resistance spot welding (RSW) process. RSW method was modeled numerically and investigated experimentally by using different welding parameters. In numerical modeling, material properties and process parameters were modeled with the finite element method (FEM), and simulations were realized in experimentally performed

Argon–helium mixtures in gas tungsten arc welding of an iron workpiece are investigated using an axisymmetric computational model that includes the cathode, workpiece, and arc plasma in the computational domain. The three-gas combined diffusion coefficient method is used to treat diffusion of helium, argon, and iron vapour. Calculations for argon–helium mixtures without metal vapour are performed;

This paper examined the joining zone between semi-crystalline polyamide 6 and aluminum EN AW 6082 in laser-based joining and evaluated the mechanical properties of the joint. The joint tests were carried out in overlap configuration and a characterized in terms of energy per unit length. The mechanical properties were examined to the point of cohesive failure. An increasing energy per unit length resulted

The friction stir welding (FSW) process is known as a solid-state welding process, comparatively stable against external influences. Therefore, the process is commonly used with fixed welding parameters, utilizing axial force control or position control strategies. External and internal process disturbances introduced by workpiece, gap tolerance, tool wear, or machine/tool inadequacies are rarely monitored

A simplified surface heat source for gas metal arc welding (GMAW) process simulation based on the principle of evaporation determined arc cathode coupling (EDACC) is presented. It allows for a simple implementation in any GMAW weld pool simulation and is dependent on the width of the arc, as well as the weld pool surface temperature, but it can also be applied with the temperature and iron vapor density

Residual stresses in welded joints are often of extended interest in order to evaluate unexpected failures or distortions. Since the possibilities to calculate residual stresses in welds are still strongly limited, the measurement techniques are still of great importance. Several measurement techniques with particular possibilities and limitations are available today where especially the different

This research work is the first step in evaluating the feasibility of producing industrial components by using Laser Metal Deposition with duplex stainless steel Wire (LMDw). The influence of Ar and N2 shielding gases was investigated in terms of nitrogen loss and in the microstructure and austenite content of different deposited geometries. The evolution of the microstructure in the build-up direction

The laser impulse metal bonding (LIMBO) process opens a new possibility to join a thick interconnector on a thin metal layer which lays on a sensitive substrate such as epoxy resin (FR4) material. Since the FR4 tolerates only limited amount of the thermal load during the joining process, the LIMBO process applies a novel approach to separate the melting and joining phase. Hence, the thermal load on

The increasing demand for energy-efficient vehicles requires suitable methods for cost and weight reduction. This can be achieved by the replacement of copper by aluminum, in particular for the on-board power systems. However, the complete substitution is restricted by the mechanical and physical material properties of aluminum as well as challenges in the aluminum copper interface. The challenges

The article attempts to detect the defects in friction stir welding (FSW) process by analyzing the signal acquired during welding. The said welding technique utilizes pressure and heat developed by the usage of a non-consumable tool. Thus, the axial force signal carries a lot of information about the physical process, and hence, it could be used to identify the weld defects. Signal analysis has been

This study investigates friction stir welding (FSW) in the dissimilar joining process of cladded plates. Samples of 4-mm thick ASTM 572 steel plate cladded with 3-mm thick Inconel®625 represent the base material. In order to limit mixing between the dissimilar materials to keep the corrosion resistance, a two-pass welding procedure was applied. Optimal welding parameters for each pass were identified

Orthotropic steel decks are composed of comparatively thin steel plates (as thin as 6 mm) that deform in the in-plane and out-of-plane directions at longitudinal-to-transverse rib connections in response to vehicle loads. Since such deformations can change as the load positions move, local stress directions can also vary such that hot spots along the weld toes are moved and the relationship between

Weld defect recognition plays an important role in the manufacturing process of large-scale equipment. Traditional methods generally include several serial steps, such as image preprocessing, region segmentation, feature extraction, and type recognition. The results of each step have significant impact on the accuracy of the final defect identification. The convolutional neural network (CNN) has strong

The microstructural characteristics of the local brittle layer (LBL) reported to be formed at the weld center of tandem electro-gas (EG) weld made with EG70T-G wire have been investigated to identify the critical factors causing its brittleness and thus facilitate the development of welds free from the local brittle layer. The results showed that in addition to the directional characteristics of columnar

Avoiding low austenite fractions and nitride formation are major challenges in laser welding of duplex stainless steels (DSS). The present research aims at investigating efficient means of promoting austenite formation during autogenous laser welding of DSS without sacrificing productivity. In this study, effects of shielding gas and laser reheating were investigated in welding of 1.5-mm-thick FDX

Titanium alloys are supreme structural materials primarily due to their high specific strength. However, their wide use is largely restrained by the high cost of raw titanium compared to other metals commonly used in structural alloys. Layered structures of titanium alloys allow substantial increase of the material utilisation ratio and therefore draw significant attention. The rational ways of layered

This paper investigates the fatigue strength enhancement of two types of peening techniques: hammer peening with impact crack-closure retrofit apparatus and high-frequency mechanical impact (HFMI) treatment on out-of-plane gusset-welded joints made of SBHS700. In this work, fatigue tests were continuously carried out using plate specimens that were removed from a previously tested girder specimen.

In this paper, the effect of plasma arc welding (PAW) process parameters on the mechanical properties and macro- and microstructure of Ti-6Al-4V alloy is discussed. These parameters including welding current, welding speed, and plasma gas orifice diameter have an effect on the weld bead depth and width. Macrograph results indicate that there is a certain range of welding electric current and welding

Dissimilar transient liquid phase (TLP) bonding of GTD-111 and IN-718 nickel-based superalloys was investigated using BNi-9 (AWS A5.8/A5.8M) as an interlayer. The effect of the bonding time on the microstructure and mechanical properties of the TLP-bonded specimens was studied at 1100 °C using optical microscopy (OM), scanning electron microscopy (SEM) equipped with energy-dispersive spectrometry (EDS)

Numerous studies report a wide range of possible applications for refill friction stir spot welding, reaching from light metal alloys and cast materials to mixed construction applications. In order to make use of these potentials, it is necessary to enhance the tool concept with the aim to increase tool life. Previous studies have reported on different tool life quantities between 5 and 9000 spot welds

Flash butt weld process parameters determine the weld quality. The presence of weld defects due to inappropriate process parameters leads to entrapment of oxides in the weld causes premature failure. It was also observed that the flash butt process parameter is dependent on the chemistry of the steel that is processed. The high weight percentage of Mn and Si leads to a higher weight fraction of the

Hybrid structure between porous core and solid shell can combine lightweight open-cell structure of porous materials with good strength of solid shell. Laser welding is considered as an effective process to join porous metal with solid metallic shell. In this study, the evolution behavior of laser welding by a continuous wave (CW) disk laser welding between open-cell aluminum alloy (cast AC2A alloy)

Although in the last decades the applicable regulations for the design of steel structures have been deeply improved accounting for modern design approaches and technologies, in a few industrial fields, concepts and formulations derived from centuries-old experience are even nowadays the governing rule. This very often limits the potential offered by the technological innovations in high-performance

In lightweight construction, light metals like aluminum are used in addition to high-strength steels. However, a welded joint of aluminum and steel leads to the precipitation of brittle, intermetallic phases and contact corrosion. Nevertheless, to use the advantages of this combination in terms of weight saving, composite hybrid forging has been developed. In this process, an aluminum solid part and

An innovative integrated I-shape multi-layer coil was designed for the electromagnetic welding (EMW) process using the finite element method (FEM) combined with response surface methodology (RSM) to minimize the required discharge energy of welding. The parameters of number of layers (n), thickness of layers (t), and distance between layers (d) have been varied to optimize the values of current peak

Stainless austenitic (0.12C-18Cr-10Ni-Ti, wt-%) and ferritic-martensitic (0.16C-12Cr-Mo-Si-V-Nb-B, wt-%) steels were joined by transient liquid phase diffusion bonding (also called diffusion brazing) with the filler metals based on Ni-Cr-Si-(Fe)-B at 1160 °C for different bonding times from 15 to 40 min. It is shown that the braze joints have a heterogeneous diffusion zone with a boride network which

Conventional fusion welding of dissimilar metals is often limited due to the different thermo-physical properties of the joining partners. In consequence, brittle intermetallic phases (IMC) can occur. Utilizing a pressure welding process like magnetic pulse welding (MPW) reduces the risk of IMCs significantly. Furthermore, this welding process has an outstanding short process duration in the range

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