Pub Date : 2025-06-01Epub Date: 2025-02-18DOI: 10.1016/j.jajp.2025.100295
E. Ajenifuja , A.P.I. Popoola , O. Popoola
Duplex stainless steel (DSS) possesses wide range of useful metallographic and mechanical properties; hence the material has been used in different forms of application namely in chloride present environments such as desalination plants and cooling water services such as conventional and nuclear power stations. However, this material has its limitations as it's susceptible to cracking particularly stress corrosion cracking or pitting corrosion and can exhibit poor metallurgical properties such as microstructures and phase containing unbalanced proportions of ferrite and austenite. In this study, Flux Core Arc Welding (FCAW) is compared with Shielded Metal Arch Welding (SMAW) process, in terms of their effects on the structural and mechanical properties and performances of DSS weldments. Analysis of the microstructure and phases were carried out. Also, the tensile, microhardness, impact and fracture properties were determined with relevant techniques. The results indicated that SMAW and FCAW welding processes differentially influence the structural and mechanical properties of the DSS weldments, consisting of the part of base material, weld and the heat affected zone (HAZ). The weld prepared using the SMAW process exhibited superior hardness characteristics at 309 HV and achieved the highest impact energy absorption of 145.92 J. In contrast, the FCAW prepared weldment exhibited the highest tensile strength, reaching 282.30 kN maximum load.
{"title":"Comparative analysis of structural and mechanical properties of duplex stainless steel (DSS) weldments prepared by flux core arc welding and shielded metal arch welding processes","authors":"E. Ajenifuja , A.P.I. Popoola , O. Popoola","doi":"10.1016/j.jajp.2025.100295","DOIUrl":"10.1016/j.jajp.2025.100295","url":null,"abstract":"<div><div>Duplex stainless steel (DSS) possesses wide range of useful metallographic and mechanical properties; hence the material has been used in different forms of application namely in chloride present environments such as desalination plants and cooling water services such as conventional and nuclear power stations. However, this material has its limitations as it's susceptible to cracking particularly stress corrosion cracking or pitting corrosion and can exhibit poor metallurgical properties such as microstructures and phase containing unbalanced proportions of ferrite and austenite. In this study, Flux Core Arc Welding (FCAW) is compared with Shielded Metal Arch Welding (SMAW) process, in terms of their effects on the structural and mechanical properties and performances of DSS weldments. Analysis of the microstructure and phases were carried out. Also, the tensile, microhardness, impact and fracture properties were determined with relevant techniques. The results indicated that SMAW and FCAW welding processes differentially influence the structural and mechanical properties of the DSS weldments, consisting of the part of base material, weld and the heat affected zone (HAZ). The weld prepared using the SMAW process exhibited superior hardness characteristics at 309 HV and achieved the highest impact energy absorption of 145.92 <em>J</em>. In contrast, the FCAW prepared weldment exhibited the highest tensile strength, reaching 282.30 kN maximum load.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100295"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143453796","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-04-04DOI: 10.1016/j.jajp.2025.100302
Eyuel A. Lemma , João M.S. Dias , António A. Bastos , Bernardo Mascate , Ana Horovistiz
Induction brazing is emerging as a promising technique in current manufacturing processes, particularly noted for its effectiveness in the precise control of heat input, localized heating and rapid processing time. This joining technique is advantageous in industries such as heat pump and refrigeration manufacturing, which require precise and effective joining techniques, particularly for brazing copper and dissimilar metal pipes. Additionally, this technique is environmentally friendly, energy-efficient, cost-effective, and well-suited for automation.
However, studies have shown that induction brazing of copper and dissimilar metals presents several significant challenges, including thermal distortion-induced cracks due to unoptimized heat input and porosity defects stemming from inadequate filler metal penetration and suboptimal gap size between the joint, these issues can compromise joint integrity, as well as system durability and sustainability. Furthermore, the incompatible thermophysical properties of dissimilar materials and interconnectors pose substantial difficulties in achieving complete metallurgical bonding. The formation of undesirable microstructures, such as hard and brittle intermetallic compounds (IMCs), can further affect the structural, mechanical, and thermal properties of brazed joints.
This review systematically examines the effects of the most significant induction brazing process parameters on joint performance. Specifically, the effects of heat input, geometrical gap size between the joints, and composition of the filler material on the quality of brazed joints are discussed. Moreover, this review explores the induction brazing of copper with dissimilar metals, including copper with aluminum and copper with stainless steel. The impact of key process parameters on the joint quality of these materials was analyzed. Additionally, opportunities, challenges, and strategies to mitigate the challenges in induction brazing of copper and dissimilar metals are presented induction brazing are presented along with future research directions.
{"title":"Advances in induction brazing of copper and dissimilar metals: Challenges and emerging trends","authors":"Eyuel A. Lemma , João M.S. Dias , António A. Bastos , Bernardo Mascate , Ana Horovistiz","doi":"10.1016/j.jajp.2025.100302","DOIUrl":"10.1016/j.jajp.2025.100302","url":null,"abstract":"<div><div>Induction brazing is emerging as a promising technique in current manufacturing processes, particularly noted for its effectiveness in the precise control of heat input, localized heating and rapid processing time. This joining technique is advantageous in industries such as heat pump and refrigeration manufacturing, which require precise and effective joining techniques, particularly for brazing copper and dissimilar metal pipes. Additionally, this technique is environmentally friendly, energy-efficient, cost-effective, and well-suited for automation.</div><div>However, studies have shown that induction brazing of copper and dissimilar metals presents several significant challenges, including thermal distortion-induced cracks due to unoptimized heat input and porosity defects stemming from inadequate filler metal penetration and suboptimal gap size between the joint, these issues can compromise joint integrity, as well as system durability and sustainability. Furthermore, the incompatible thermophysical properties of dissimilar materials and interconnectors pose substantial difficulties in achieving complete metallurgical bonding. The formation of undesirable microstructures, such as hard and brittle intermetallic compounds (IMCs), can further affect the structural, mechanical, and thermal properties of brazed joints.</div><div>This review systematically examines the effects of the most significant induction brazing process parameters on joint performance. Specifically, the effects of heat input, geometrical gap size between the joints, and composition of the filler material on the quality of brazed joints are discussed. Moreover, this review explores the induction brazing of copper with dissimilar metals, including copper with aluminum and copper with stainless steel. The impact of key process parameters on the joint quality of these materials was analyzed. Additionally, opportunities, challenges, and strategies to mitigate the challenges in induction brazing of copper and dissimilar metals are presented induction brazing are presented along with future research directions.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100302"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143807123","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-01-16DOI: 10.1016/j.jajp.2025.100286
R.F. Rezende , A.R. Arias , E.J. Lima II , F.G.F. Coelho
This study aimed to introduce pulsed gas metal arc welding (GMAW)-based wire arc additive manufacturing (WAAM) for the deposition of 308 L stainless steel. Then, the influence of the different droplet detachment modes on the geometric characteristics and mechanical properties of the deposited metal were analyzed. The detachment modes of one drop per multiple pulses (ODMP), one drop per pulse (ODPP), and multiple drops per pulse (MDPP) were analyzed. The experiments were performed by depositing preforms using 308 L stainless steel wire with a diameter of 1.0 mm on a 316 L stainless steel substrate. Characterization of the droplet detachment modes was performed using a high-speed camera and data acquisition system. Geometric analysis of the preforms was performed by photogrammetry. A greater heat input was observed in the ODMP mode. The MDPP and ODPP modes produced thinner preforms with a better surface finish. In addition, the MDPP mode generated better results in the manufactured preforms, with lower hardness and higher tensile strength. However, the ODMP mode led to relatively poorer results, with wider walls, greater surface waviness, and lower tensile strength. The results of this research are expected to provide technical and scientific support for the development of additive manufacturing by arc deposition, especially for stainless steel applications.
{"title":"Pulsed GMAW-based WAAM–Influence of droplet detachment mode on the geometry and mechanical properties of 308 L stainless steel","authors":"R.F. Rezende , A.R. Arias , E.J. Lima II , F.G.F. Coelho","doi":"10.1016/j.jajp.2025.100286","DOIUrl":"10.1016/j.jajp.2025.100286","url":null,"abstract":"<div><div>This study aimed to introduce pulsed gas metal arc welding (GMAW)-based wire arc additive manufacturing (WAAM) for the deposition of 308 L stainless steel. Then, the influence of the different droplet detachment modes on the geometric characteristics and mechanical properties of the deposited metal were analyzed. The detachment modes of one drop per multiple pulses (ODMP), one drop per pulse (ODPP), and multiple drops per pulse (MDPP) were analyzed. The experiments were performed by depositing preforms using 308 L stainless steel wire with a diameter of 1.0 mm on a 316 L stainless steel substrate. Characterization of the droplet detachment modes was performed using a high-speed camera and data acquisition system. Geometric analysis of the preforms was performed by photogrammetry. A greater heat input was observed in the ODMP mode. The MDPP and ODPP modes produced thinner preforms with a better surface finish. In addition, the MDPP mode generated better results in the manufactured preforms, with lower hardness and higher tensile strength. However, the ODMP mode led to relatively poorer results, with wider walls, greater surface waviness, and lower tensile strength. The results of this research are expected to provide technical and scientific support for the development of additive manufacturing by arc deposition, especially for stainless steel applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100286"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133073","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Degradation is a common phenomenon in gas turbine components. Among additive manufacturing (AM) methods like direct laser deposition (DLD) and laser powder bed fusion (LPBF), DLD has been widely studied due to its ease in repair processes. However, LPBF offers higher dimensional accuracy, better surface quality, and reduced stress. This study employed LPBF of IN625 on an IN738 substrate for repair purposes. A wide range of process parameters (power at 100, 150, and 200 W and scan speeds between 100 mm/s to 2700 mm/s) was evaluated. The reasons behind process parameters' influence on defect formation, such as pores and cracks, were investigated, as these aspects have been less emphasized in prior studies. The relationship between process parameters, melt pool shape, pore formation, and changes in elemental concentration was explored. It was found that concentration peaks at the interface are the main factor in crack formation, enabling predictions of cracking behavior. Elements diffuse from rich to poor regions at the IN625/IN738 interface. At scan speeds ≤ 500 mm/s, increasing speed and power both increase elemental concentration at the interface, but speed promotes elemental accumulation behind the interface, while power enhances homogenization. The effect of process parameters on microhardness and cell size was also examined. It was determined that cracks do not form in softer nickel-based matrices where microhardness remains below the critical threshold of 256 HV.
{"title":"A new approach to the reasons for dependency of defects formation to the process parameters in laser powder bed fusion of IN625 on the IN738LC substrate","authors":"Amirhossein Riazi , Seyed Hossein Razavi , Alireza Khavandi , Mostafa Amirjan , Mohsen Ostad Shabani , Hossein Davarzani","doi":"10.1016/j.jajp.2024.100273","DOIUrl":"10.1016/j.jajp.2024.100273","url":null,"abstract":"<div><div>Degradation is a common phenomenon in gas turbine components. Among additive manufacturing (AM) methods like direct laser deposition (DLD) and laser powder bed fusion (LPBF), DLD has been widely studied due to its ease in repair processes. However, LPBF offers higher dimensional accuracy, better surface quality, and reduced stress. This study employed LPBF of IN625 on an IN738 substrate for repair purposes. A wide range of process parameters (power at 100, 150, and 200 W and scan speeds between 100 mm/s to 2700 mm/s) was evaluated. The reasons behind process parameters' influence on defect formation, such as pores and cracks, were investigated, as these aspects have been less emphasized in prior studies. The relationship between process parameters, melt pool shape, pore formation, and changes in elemental concentration was explored. It was found that concentration peaks at the interface are the main factor in crack formation, enabling predictions of cracking behavior. Elements diffuse from rich to poor regions at the IN625/IN738 interface. At scan speeds ≤ 500 mm/s, increasing speed and power both increase elemental concentration at the interface, but speed promotes elemental accumulation behind the interface, while power enhances homogenization. The effect of process parameters on microhardness and cell size was also examined. It was determined that cracks do not form in softer nickel-based matrices where microhardness remains below the critical threshold of 256 HV.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100273"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133037","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-05-16DOI: 10.1016/j.jajp.2025.100312
Maja Lindič , Damjan Klobčar , Aleš Nagode , Nikolaj Mole , Borut Žužek , Tomaž Vuherer
This article deals with the Directed Energy Deposition using Wire and Arc (DED-ARC) for maraging steel cladding. A technology for cladding using Gas Metal Arc Welding (GMAW) has been developed that enables the perfect deposition of maraging steel. The material characterisation was carried out in different material states: in the as-built, solution annealed and aged. The research included visual examinations, optical microscopy, Scanning Electron Microscopy / Energy-dispersive X-ray spectroscopy (SEM/EDS), fractography, hardness testing, tensile testing and impact toughness testing. The as-deposited state exhibited a microstructure with very long crystal grains and microsegregations orientated the direction of the heat sink, consisting of lath martensite. Consequently, a subsequent heat treatment is absolutely necessary in order to obtain a uniform fine-grained microstructure. Two different solution annealing processes were analysed, which allowed us to select the most suitable process for the first step of heat treatment followed by aging. A response surface methodology was used to optimise the aging conditions. The results show that additively manufactured maraging steel reaches a tensile strength of 1947 MPa, a hardness of 657 HV5 and a Charpy impact toughness of 11 J at peak aging condition, which is comparable to conventionally manufactured maraging steel.
{"title":"Heat treatment optimisation of 18 % Ni maraging steel produced by DED-ARC for enhancing mechanical properties","authors":"Maja Lindič , Damjan Klobčar , Aleš Nagode , Nikolaj Mole , Borut Žužek , Tomaž Vuherer","doi":"10.1016/j.jajp.2025.100312","DOIUrl":"10.1016/j.jajp.2025.100312","url":null,"abstract":"<div><div>This article deals with the Directed Energy Deposition using Wire and Arc (DED-ARC) for maraging steel cladding. A technology for cladding using Gas Metal Arc Welding (GMAW) has been developed that enables the perfect deposition of maraging steel. The material characterisation was carried out in different material states: in the as-built, solution annealed and aged. The research included visual examinations, optical microscopy, Scanning Electron Microscopy / Energy-dispersive X-ray spectroscopy (SEM/EDS), fractography, hardness testing, tensile testing and impact toughness testing. The as-deposited state exhibited a microstructure with very long crystal grains and microsegregations orientated the direction of the heat sink, consisting of lath martensite. Consequently, a subsequent heat treatment is absolutely necessary in order to obtain a uniform fine-grained microstructure. Two different solution annealing processes were analysed, which allowed us to select the most suitable process for the first step of heat treatment followed by aging. A response surface methodology was used to optimise the aging conditions. The results show that additively manufactured maraging steel reaches a tensile strength of 1947 MPa, a hardness of 657 HV5 and a Charpy impact toughness of 11 J at peak aging condition, which is comparable to conventionally manufactured maraging steel.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100312"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144098349","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-01-31DOI: 10.1016/j.jajp.2025.100290
A. Baghbani Barenji , M.B. Russo , S. Jabar , H.R. Kotadia , D. Ceglarek , K.F. Ayarkwa , J.R. Smith , P. Franciosa
Using a continuous wave (CW) laser with beam oscillation, this study elucidates the impact of passive and active cooling on welding hot-dip galvanised steel-to-aluminium sheets. The work investigates how cooling affects the formation of intermetallic compounds (IMCs) and the behaviour of Zn vapours, both of which are critical factors to the joint strength. IMCs are recognised as the most decisive factor in welding steel to aluminium, while Zn vapours significantly impact welding in a zero part-to-part gap overlap configuration. A 3D finite element method thermal model was employed to correlate the thermal cycles to the metallurgical and mechanical properties. The cooling rate without beam oscillation increased by 34% switching from passive to active cooling, while it was only 2.5% with oscillation present (2.5 mm lateral oscillation). Results revealed that active cooling influences Zn vapours and IMCs differently; faster cooling reduced total IMCs and Fe2Al5 phase and increased joint strength; however, it exacerbated spattering and weld discontinuity due to insufficient time for outgassing the Zn vapours from the molten pool. This adverse effect was more pronounced with beam oscillation due to larger molten pool. The experimental work also showed that despite beam oscillation does enlarge the connection area, the average shear stress was relatively lower compared to the case without oscillation, attributed to the increased thickness of the IMCs. Active cooling with water flow at 10 °C achieved 60% joint efficiency compared to parent aluminium, while beam oscillation reduced this to 54% but with half the strength variation. This highlights the complex, non-linear interplay between IMC formation, Zn vapour outgassing, and the dynamics of the molten pool.
{"title":"Effect of cooling rate on metallurgical and mechanical properties in continuous wave laser welding of hot-dip galvanised steel-to-aluminium sheets in a zero part-to-part gap lap joint configuration","authors":"A. Baghbani Barenji , M.B. Russo , S. Jabar , H.R. Kotadia , D. Ceglarek , K.F. Ayarkwa , J.R. Smith , P. Franciosa","doi":"10.1016/j.jajp.2025.100290","DOIUrl":"10.1016/j.jajp.2025.100290","url":null,"abstract":"<div><div>Using a continuous wave (CW) laser with beam oscillation, this study elucidates the impact of passive and active cooling on welding hot-dip galvanised steel-to-aluminium sheets. The work investigates how cooling affects the formation of intermetallic compounds (IMCs) and the behaviour of Zn vapours, both of which are critical factors to the joint strength. IMCs are recognised as the most decisive factor in welding steel to aluminium, while Zn vapours significantly impact welding in a zero part-to-part gap overlap configuration. A 3D finite element method thermal model was employed to correlate the thermal cycles to the metallurgical and mechanical properties. The cooling rate without beam oscillation increased by 34% switching from passive to active cooling, while it was only 2.5% with oscillation present (2.5 mm lateral oscillation). Results revealed that active cooling influences Zn vapours and IMCs differently; faster cooling reduced total IMCs and Fe<sub>2</sub>Al<sub>5</sub> phase and increased joint strength; however, it exacerbated spattering and weld discontinuity due to insufficient time for outgassing the Zn vapours from the molten pool. This adverse effect was more pronounced with beam oscillation due to larger molten pool. The experimental work also showed that despite beam oscillation does enlarge the connection area, the average shear stress was relatively lower compared to the case without oscillation, attributed to the increased thickness of the IMCs. Active cooling with water flow at 10 °C achieved 60% joint efficiency compared to parent aluminium, while beam oscillation reduced this to 54% but with half the strength variation. This highlights the complex, non-linear interplay between IMC formation, Zn vapour outgassing, and the dynamics of the molten pool.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100290"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143350465","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-02-15DOI: 10.1016/j.jajp.2025.100292
Aravind Babu, Emiliano Trodini, José Luis Galán Argumedo, Ian M. Richardson, Marcel J.M. Hermans
Wire arc additive manufacturing (WAAM) of high-strength steel (HSS) has gained significant attention for structural applications. Achieving precise control over the manufacturing process and understanding the relationship between process parameters and the resulting material characteristics is crucial for optimizing the performance of these steel walls to achieve tailored properties. The present study was performed to comprehend the influence of process parameters on the microstructure and properties of wire arc additively manufactured (WAAM) high-strength steel (HSS) thin-wall structures. Multi-layer thin walls of ER110S-G high-strength steel comprising 30 layers were deposited bidirectionally and were fabricated with different travel speeds and wire-feed rates. Geometrical analysis conducted on samples indicates that achieving minimal surface waviness for single-bead thin walls depends on adjusting wire feed rates and travel speeds. Specifically, lower wire feed rates are found to be more effective in minimizing waviness when dealing with single-bead thin walls (thickness 5 mm). Conversely, lower travel speeds are preferred for reducing surface irregularities in walls fabricated at high deposition rates for thicker single-bead walls (thickness 8 mm). Cooling rate analysis from midpoints of the 5th, 15th and 25th layers of each sample indicates high cooling rates for low heat input (HI=178 J/mm) samples even for the layer. Microstructural characterization of the samples suggests an increase in acicular ferrite and martensite volume fraction with lower heat input. Additionally, microstructural quantification with EBSD reveals smaller grain sizes and higher Kernel average misorientation for low heat input deposits. Mechanical properties like hardness and tensile strength display an increasing trend with decreasing heat input while elongation to fracture is reduced under the same conditions. Furthermore, anisotropic behaviour is observed in tensile strength and elongation to fracture between building and deposition directions due to the presence of microstructural inhomogeneities.
{"title":"Correlating geometry, microstructure and properties of High Strength Steel thin wall structures fabricated with WAAM","authors":"Aravind Babu, Emiliano Trodini, José Luis Galán Argumedo, Ian M. Richardson, Marcel J.M. Hermans","doi":"10.1016/j.jajp.2025.100292","DOIUrl":"10.1016/j.jajp.2025.100292","url":null,"abstract":"<div><div>Wire arc additive manufacturing (WAAM) of high-strength steel (HSS) has gained significant attention for structural applications. Achieving precise control over the manufacturing process and understanding the relationship between process parameters and the resulting material characteristics is crucial for optimizing the performance of these steel walls to achieve tailored properties. The present study was performed to comprehend the influence of process parameters on the microstructure and properties of wire arc additively manufactured (WAAM) high-strength steel (HSS) thin-wall structures. Multi-layer thin walls of ER110S-G high-strength steel comprising 30 layers were deposited bidirectionally and were fabricated with different travel speeds and wire-feed rates. Geometrical analysis conducted on samples indicates that achieving minimal surface waviness for single-bead thin walls depends on adjusting wire feed rates and travel speeds. Specifically, lower wire feed rates are found to be more effective in minimizing waviness when dealing with single-bead thin walls (thickness <span><math><mo><</mo></math></span> 5 mm). Conversely, lower travel speeds are preferred for reducing surface irregularities in walls fabricated at high deposition rates for thicker single-bead walls (thickness <span><math><mo>></mo></math></span> 8 mm). Cooling rate analysis from midpoints of the 5th, 15th and 25th layers of each sample indicates high cooling rates for low heat input (HI=178 J/mm) samples even for the <span><math><mrow><mn>25</mn><mi>th</mi></mrow></math></span> layer. Microstructural characterization of the samples suggests an increase in acicular ferrite and martensite volume fraction with lower heat input. Additionally, microstructural quantification with EBSD reveals smaller grain sizes and higher Kernel average misorientation for low heat input deposits. Mechanical properties like hardness and tensile strength display an increasing trend with decreasing heat input while elongation to fracture is reduced under the same conditions. Furthermore, anisotropic behaviour is observed in tensile strength and elongation to fracture between building and deposition directions due to the presence of microstructural inhomogeneities.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100292"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143464927","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
A layered composite of AA1050-AA5052 alloys was fabricated through roll bonding, and accumulative roll bonding (ARB) and subsequently subjected to friction stir processing (FSP). In this process, the annealed AA5052 and AA1050 sheets are used as raw materials. At first, preheating at 200 °C for 6 min preceded the rolling process in an induction furnace, achieving a 67 % reduction in the cross-sectional area. Then, two ARB stages were conducted. At the flow, the FSP process was conducted at constant transversal speeds of 750 rpm and 1180 rpm. Microstructural details were analyzed using optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD). Mechanical properties were assessed through tensile test, microhardness measurement, and wear test. The results showed that recrystallization occurred due to FSP applied to the rolled sheet. The tensile strength after ARB and FSP was measured as 270 and 150 MPa, respectively. These values show an increase of 3.3 times and 1.8 times, respectively, compared to annealed AA1050. The maximum elongation after ARB and FSP was measured at about 9 and 30 %. Work hardening and grain refinement, respectively, had a significant role in increasing the elongation of the AA1050/AA5052 composites created by ARB and FSP. Furthermore, FSP enhanced the wear resistance of the AA1050-AA5052 composite created with two ARB steps by 70 %.
{"title":"Friction stir processing of AA1050/AA5052 composite produced by accumulative roll bonding process: Microstructure and mechanical properties","authors":"Hamid Partoyar , Hamid Reza Jafarian , Hamed Roghani , Ahad Mohammadzadeh , Akbar Heidarzadeh","doi":"10.1016/j.jajp.2025.100306","DOIUrl":"10.1016/j.jajp.2025.100306","url":null,"abstract":"<div><div>A layered composite of AA1050-AA5052 alloys was fabricated through roll bonding, and accumulative roll bonding (ARB) and subsequently subjected to friction stir processing (FSP). In this process, the annealed AA5052 and AA1050 sheets are used as raw materials. At first, preheating at 200 °C for 6 min preceded the rolling process in an induction furnace, achieving a 67 % reduction in the cross-sectional area. Then, two ARB stages were conducted. At the flow, the FSP process was conducted at constant transversal speeds of 750 rpm and 1180 rpm. Microstructural details were analyzed using optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD). Mechanical properties were assessed through tensile test, microhardness measurement, and wear test. The results showed that recrystallization occurred due to FSP applied to the rolled sheet. The tensile strength after ARB and FSP was measured as 270 and 150 MPa, respectively. These values show an increase of 3.3 times and 1.8 times, respectively, compared to annealed AA1050. The maximum elongation after ARB and FSP was measured at about 9 and 30 %. Work hardening and grain refinement, respectively, had a significant role in increasing the elongation of the AA1050/AA5052 composites created by ARB and FSP. Furthermore, FSP enhanced the wear resistance of the AA1050-AA5052 composite created with two ARB steps by 70 %.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100306"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143903677","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-05-20DOI: 10.1016/j.jajp.2025.100315
Dominik Rauner, Niklas Eilers, Hannes Panzer, Lukas Frei, Michael F. Zaeh
Powder bed fusion of metals using a laser beam (PBF-LB/M) enables the near-net-shape fabrication of thin-walled parts with a high geometric complexity, thus often featuring structural transitions. Due to high temperature gradients during manufacturing, these structural transitions are subject to localized deformations, which manifest themselves in a shrink line, which is reducing the part lifetime and the dimensional accuracy. In current PBF-LB/M process simulations, however, the shrink line formation cannot be predicted on a physical basis yet. In this study, a finite element approach for efficiently predicting the shrink line formation is presented. The three-stage approach begins with a numerical geometry analysis, which is used to define an appropriate finite element mesh for the subsequent analyses. This is followed by the prediction of the geometry-dependent overheating during the PBF-LB/M process. Using these overheating results and an experimentally calibrated overheating-shrink-line relation, the shrink lines are modeled in a mechanical analysis considering the physics-based effects. The simulation approach was verified on an academic specimen design and was experimentally validated on two parts with different degrees of geometric complexity. The derived overheating-shrink-line relation provided a valid strategy for predicting the resulting shrink line depth. Applying the approach, the deviation between the measurements and the shrink line simulation was determined to be lower than 41 µm. Furthermore, the prediction quality of the dimensional accuracy was increased by 6.9 % for a topology-optimized part. For the approach, necessary extensions were derived to allow for simulating an asymmetric shrink line formation in the future.
{"title":"Prediction of shrink lines in powder bed fusion of metals using a laser beam by means of a finite element simulation approach","authors":"Dominik Rauner, Niklas Eilers, Hannes Panzer, Lukas Frei, Michael F. Zaeh","doi":"10.1016/j.jajp.2025.100315","DOIUrl":"10.1016/j.jajp.2025.100315","url":null,"abstract":"<div><div>Powder bed fusion of metals using a laser beam (PBF-LB/M) enables the near-net-shape fabrication of thin-walled parts with a high geometric complexity, thus often featuring structural transitions. Due to high temperature gradients during manufacturing, these structural transitions are subject to localized deformations, which manifest themselves in a shrink line, which is reducing the part lifetime and the dimensional accuracy. In current PBF-LB/M process simulations, however, the shrink line formation cannot be predicted on a physical basis yet. In this study, a finite element approach for efficiently predicting the shrink line formation is presented. The three-stage approach begins with a numerical geometry analysis, which is used to define an appropriate finite element mesh for the subsequent analyses. This is followed by the prediction of the geometry-dependent overheating during the PBF-LB/M process. Using these overheating results and an experimentally calibrated overheating-shrink-line relation, the shrink lines are modeled in a mechanical analysis considering the physics-based effects. The simulation approach was verified on an academic specimen design and was experimentally validated on two parts with different degrees of geometric complexity. The derived overheating-shrink-line relation provided a valid strategy for predicting the resulting shrink line depth. Applying the approach, the deviation between the measurements and the shrink line simulation was determined to be lower than 41 µm. Furthermore, the prediction quality of the dimensional accuracy was increased by 6.9 % for a topology-optimized part. For the approach, necessary extensions were derived to allow for simulating an asymmetric shrink line formation in the future.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100315"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144220957","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
An innovative anti-loosening bolt with a double-thread mechanism (denoted as DTB-IIC) consisting of coaxial single and multiple coarse threads was previously devised and its structure and performance were optimized. The results of a previous study showed that increasing the bottom rise ratio , which is the ratio of the bottom rise for the multi-thread groove to the thread height, to 70 % significantly improved the formability during the thread-rolling process, but clearly reduced the loosening resistance. In the present study, an attempt was made to address this problem in a simple manner by inserting a left-handed spring washer (SW) between the inner multi-thread nut and the outer single-thread nut. The value of was set to 50 %, 60 %, or 70 %. Comparative Junker vibration loosening tests based on the ISO 16,130 standard were conducted and the change in the residual ratio for the axial load, , was evaluated. Without the SW, the final () for was above 90 %, while for and , it was approximately 73 % and 64 %, respectively. Attachment of the SW caused an increase in for all values, with a greater increase for larger , reaching 82 % for = 60 % and 75 % for = 70 %, respectively. It was found that the contact force between the nuts is an indicator for determining the degree of locking between the DTB-IIC and the nut. The initial loosening process was simulated using a three-dimensional finite element method model, and the curves obtained in the analysis agreed well with the experimental results by setting the gap between the inner multi-thread nut and the DTB-IIC bolt in the range 0.125–0.15 mm. The simulation results indicated that there were clear differences in mating state between the outer nut and the DTB-IIC depending on the value, and the use of a SW achieved a more robust locking state when was 50 %.
{"title":"Improvement of anti-loosening resistance of locking bolts based on single-coarse-thread/multiple-coarse-thread mechanism by using spring washer between nuts","authors":"Shuichi Amano , Toshinaka Shinbutsu , Yuki Okimoto , Teruie Takemasu , Toshihiko Kuwabara","doi":"10.1016/j.jajp.2025.100280","DOIUrl":"10.1016/j.jajp.2025.100280","url":null,"abstract":"<div><div>An innovative anti-loosening bolt with a double-thread mechanism (denoted as DTB-IIC) consisting of coaxial single and multiple coarse threads was previously devised and its structure and performance were optimized. The results of a previous study showed that increasing the bottom rise ratio <span><math><mi>β</mi></math></span>, which is the ratio of the bottom rise for the multi-thread groove to the thread height, to 70 % significantly improved the formability during the thread-rolling process, but clearly reduced the loosening resistance. In the present study, an attempt was made to address this problem in a simple manner by inserting a left-handed spring washer (SW) between the inner multi-thread nut and the outer single-thread nut. The value of <span><math><mi>β</mi></math></span> was set to 50 %, 60 %, or 70 %. Comparative Junker vibration loosening tests based on the ISO 16,130 standard were conducted and the change in the residual ratio for the axial load, <span><math><mi>κ</mi></math></span>, was evaluated. Without the SW, the final <span><math><mi>κ</mi></math></span> (<span><math><msub><mi>κ</mi><mi>f</mi></msub></math></span>) for <span><math><mrow><mi>β</mi><mo>=</mo><mn>50</mn><mspace></mspace><mo>%</mo></mrow></math></span> was above 90 %, while <span><math><msub><mi>κ</mi><mi>f</mi></msub></math></span> for <span><math><mrow><mi>β</mi><mo>=</mo><mn>60</mn><mspace></mspace><mo>%</mo></mrow></math></span> and <span><math><mrow><mi>β</mi><mo>=</mo><mn>70</mn><mspace></mspace><mo>%</mo></mrow></math></span>, it was approximately 73 % and 64 %, respectively. Attachment of the SW caused an increase in <span><math><msub><mi>κ</mi><mi>f</mi></msub></math></span> for all <span><math><mi>β</mi></math></span> values, with a greater increase for larger <span><math><mi>β</mi></math></span>, reaching 82 % for <span><math><mi>β</mi></math></span> = 60 % and 75 % for <span><math><mi>β</mi></math></span> = 70 %, respectively. It was found that the contact force between the nuts is an indicator for determining the degree of locking between the DTB-IIC and the nut. The initial loosening process was simulated using a three-dimensional finite element method model, and the <span><math><mi>κ</mi></math></span> curves obtained in the analysis agreed well with the experimental results by setting the gap <span><math><mi>δ</mi></math></span> between the inner multi-thread nut and the DTB-IIC bolt in the range 0.125–0.15 mm. The simulation results indicated that there were clear differences in mating state between the outer nut and the DTB-IIC depending on the <span><math><mi>β</mi></math></span> value, and the use of a SW achieved a more robust locking state when <span><math><mi>β</mi></math></span> was 50 %.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100280"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133078","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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