Journal of Advanced Joining Processes最新文献_第2页

Debonding-on-demand of vacuum-infused thermoplastic fibre-reinforced laminates with improved recyclability 提高可回收性的真空注入热塑性纤维增强层压板的按需脱粘

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-01 DOI: 10.1016/j.jajp.2025.100364

V. Bekas, C. Hoffmann, V.C. Beber, K. Arnaut

Debonding-on-Demand (DoD) is key in enabling recyclability and modular design of lightweight composite structures. This work investigates the effectiveness of DoD mechanisms using resistive heating modified substrates and thermally expandable particles (TEPs) on structural adhesive bonding. Methyl methacrylate adhesives are applied on vacuum-infused thermoplastic GFRP laminates with an Elium© acrylic matrix. Characterisation includes thermal imaging, DSC, lap-shear testing and fracture surface analysis. To enable localised thermal DoD-triggering, modified substrates are fabricated with integrated resistive heating elements. Thermal stimulus is applied either externally (via oven) and locally (via resistive heating). The expansion of TEPs is confirmed by optical microscopy. The most effective DoD response occurs in specimens with modified substrates without TEP, attributed to significant softening of the adhesive above its glass transition temperature. Specimens with both structural adhesive and TEP show a moderate DoD effect, though the reference strength is lower due to TEP-induced disruptions within the adhesive. Externally heated triggering of TEP yields little DoD effect. Fracture surface analysis supports these findings, showing characteristic changes consistent with adhesive softening and cohesive strength reduction. Results highlight how the incorporation of localised resistive heating elements can allow an easier recycling and reversible joining, which contrary to TEPs, can be repeated.

按需脱粘（DoD）是实现轻质复合材料结构可回收性和模块化设计的关键。这项工作研究了使用电阻加热改性基材和热膨胀颗粒（TEPs）在结构粘合剂粘合上的DoD机制的有效性。甲基丙烯酸甲酯粘合剂应用于真空注入热塑性玻璃钢层压板与Elium©丙烯酸基体。表征包括热成像、DSC、剪切测试和断口分析。为了实现局部热dod触发，改进的基板由集成的电阻加热元件制成。热刺激可以通过外部（通过烤箱）和局部（通过电阻加热）进行。光学显微镜证实了TEPs的膨胀。最有效的DoD响应发生在没有TEP的改性基板的样品中，这归因于粘合剂在其玻璃化转变温度以上的显着软化。含有结构粘合剂和TEP的试样均表现出中等的DoD效应，尽管由于TEP引起的粘合剂内部破坏，参考强度较低。外部加热触发TEP产生很少的DoD效应。断口表面分析支持这些发现，显示出与粘合剂软化和内聚强度降低一致的特征变化。结果突出了局部电阻加热元件的结合如何允许更容易的回收和可逆连接，这与TEPs相反，可以重复。

{"title":"Debonding-on-demand of vacuum-infused thermoplastic fibre-reinforced laminates with improved recyclability","authors":"V. Bekas, C. Hoffmann, V.C. Beber, K. Arnaut","doi":"10.1016/j.jajp.2025.100364","DOIUrl":"10.1016/j.jajp.2025.100364","url":null,"abstract":"<div><div>Debonding-on-Demand (DoD) is key in enabling recyclability and modular design of lightweight composite structures. This work investigates the effectiveness of DoD mechanisms using resistive heating modified substrates and thermally expandable particles (TEPs) on structural adhesive bonding. Methyl methacrylate adhesives are applied on vacuum-infused thermoplastic GFRP laminates with an Elium© acrylic matrix. Characterisation includes thermal imaging, DSC, lap-shear testing and fracture surface analysis. To enable localised thermal DoD-triggering, modified substrates are fabricated with integrated resistive heating elements. Thermal stimulus is applied either externally (via oven) and locally (via resistive heating). The expansion of TEPs is confirmed by optical microscopy. The most effective DoD response occurs in specimens with modified substrates without TEP, attributed to significant softening of the adhesive above its glass transition temperature. Specimens with both structural adhesive and TEP show a moderate DoD effect, though the reference strength is lower due to TEP-induced disruptions within the adhesive. Externally heated triggering of TEP yields little DoD effect. Fracture surface analysis supports these findings, showing characteristic changes consistent with adhesive softening and cohesive strength reduction. Results highlight how the incorporation of localised resistive heating elements can allow an easier recycling and reversible joining, which contrary to TEPs, can be repeated.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100364"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145681467","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}

引用次数: 0

Residual strain and strain evolution of dissimilar aluminium-steel friction stir lap welding during lap shear tests 异种铝-钢搅拌摩擦搭接在搭接剪切试验中的残余应变及应变演化

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-01 DOI: 10.1016/j.jajp.2025.100362

Sergio R. Soria , Florencia Malamud , Markus Strobl , Leonardo N. Tufaro , Hernán G. Svoboda

Friction Stir Lap Welding (FSLW) is a technique used to join dissimilar materials, such as aluminium alloys and steel sheets, applied in the automotive industry. The residual strain distribution generated during the process, strongly affects the mechanical performance and long-term durability of the welded components. In this study, the residual strains generated during FSLW of aluminium alloy and steel sheets were investigated using Bragg edge neutron imaging (BEI). Different combinations of thin aluminium alloy and steel sheets with thicknesses between 0.8 mm and 2 mm were analysed. 5052 and 5182 alloys, in combination with AISI 1010 carbon steel and dual phase (DP) 1000 steel were employed. Additionally, the evolution of the actual strain under lap shear tests was monitored. The presence of the steel inclusions was detected by neutron transmission imaging. The BEI results showed tensile residual strain along the longitudinal direction in the steel sheets after the welding process, in all cases displaying a M-shaped strain field. During the lap shear tests, a reduction of the actual tensile strains was observed due to the lateral contraction produced in the mechanical testing.

搅拌摩擦搭接焊（FSLW）是一种用于连接不同材料，如铝合金和钢板的技术，应用于汽车工业。焊接过程中产生的残余应变分布严重影响焊接构件的力学性能和长期耐久性。本文采用Bragg边缘中子成像（BEI）对铝合金和钢板在FSLW过程中产生的残余应变进行了研究。分析了薄铝合金与厚度在0.8 ~ 2mm之间的钢板的不同组合。采用5052和5182合金，结合AISI 1010碳钢和双相（DP） 1000钢。此外，还监测了搭接剪切试验下实际应变的演变。用中子透射成像检测了钢夹杂物的存在。BEI结果显示，焊接后钢板的拉伸残余应变沿纵向分布，均呈现m型应变场。在搭接剪切试验期间，由于力学试验中产生的侧向收缩，观察到实际拉伸应变的减少。

{"title":"Residual strain and strain evolution of dissimilar aluminium-steel friction stir lap welding during lap shear tests","authors":"Sergio R. Soria , Florencia Malamud , Markus Strobl , Leonardo N. Tufaro , Hernán G. Svoboda","doi":"10.1016/j.jajp.2025.100362","DOIUrl":"10.1016/j.jajp.2025.100362","url":null,"abstract":"<div><div>Friction Stir Lap Welding (FSLW) is a technique used to join dissimilar materials, such as aluminium alloys and steel sheets, applied in the automotive industry. The residual strain distribution generated during the process, strongly affects the mechanical performance and long-term durability of the welded components. In this study, the residual strains generated during FSLW of aluminium alloy and steel sheets were investigated using Bragg edge neutron imaging (BEI). Different combinations of thin aluminium alloy and steel sheets with thicknesses between 0.8 mm and 2 mm were analysed. 5052 and 5182 alloys, in combination with AISI 1010 carbon steel and dual phase (DP) 1000 steel were employed. Additionally, the evolution of the actual strain under lap shear tests was monitored. The presence of the steel inclusions was detected by neutron transmission imaging. The BEI results showed tensile residual strain along the longitudinal direction in the steel sheets after the welding process, in all cases displaying a M-shaped strain field. During the lap shear tests, a reduction of the actual tensile strains was observed due to the lateral contraction produced in the mechanical testing.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100362"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145614594","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}

引用次数: 0

Investigation of the weld characteristics of AA6016-T4 friction stitch welds in overlap configuration and the influence of stitch length on static and fatigue strength 研究了AA6016-T4摩擦缝焊缝重叠结构的焊接特性及缝长对静强度和疲劳强度的影响

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-01 DOI: 10.1016/j.jajp.2025.100363

Dominik Walz, Stefan Weihe, Martin Werz

High-strength, age-hardenable aluminum alloys in car body construction challenge conventional joining methods — especially in mixed-material body structures, as fusion welding is prone to hot cracking and to hydrogen porosity. As a solid-state process, friction stir welding circumvents these challenges and typically produces joints with a higher strength than fusion welding, particularly in high-strength aluminum alloys. While friction stir spot welding guns are commercially available, the joints produced with them exhibit significantly lower strength compared to linear welds. To address this issue, a friction stir welding gun capable of producing short stitch welds was developed for a possible application in car body manufacturing.

This work investigates friction stitch welds in AA6016-T4 sheet overlap joints and quantifies how the stitch length influences static strength, fatigue performance, hardness, and microstructure, compared to a continuous friction stir welded (FSW) joint. Short stitch welds obtained the highest lap-shear strength, achieving up to 83% joint efficiency, while longer welds reached between 65% and 68%. Metallography confirmed overlap-specific features, such as cold-lap imperfections in the weld, and showed that tool reentry can locally fragment the oxide line and diminish cold-lap severity, improving static strength. The fatigue performance of the stitch welds was lower than that of the strongest static condition, with short stitches particularly susceptible to notch effects due to overlap-specific features and reentry-related porosity. In general, intersecting stitch welds can surpass continuous FSW in static strength, but fatigue optimization will require mitigating the severity of the cold lap and reentry imperfections, for example, through adapted tool and pin designs.

汽车车身结构中的高强度、可时效硬化铝合金挑战了传统的连接方法，特别是在混合材料车身结构中，因为熔焊容易产生热裂和氢孔隙。作为一种固态工艺，搅拌摩擦焊接避免了这些挑战，并且通常产生比熔焊更高强度的接头，特别是在高强度铝合金中。虽然搅拌摩擦点焊枪是市售的，但与直线焊接相比，用它们生产的接头强度明显较低。为了解决这一问题，开发了一种能够产生短缝焊缝的搅拌摩擦焊枪，有望在汽车车身制造中得到应用。本文研究了AA6016-T4板重叠接头的摩擦缝焊接，并量化了与连续搅拌摩擦焊（FSW）接头相比，摩擦缝长度对静态强度、疲劳性能、硬度和微观结构的影响。短缝焊缝获得了最高的搭接剪切强度，接头效率高达83%，而长缝焊缝的接头效率在65%至68%之间。金相图证实了重叠的特定特征，例如焊缝中的冷搭缺陷，并表明工具再入可以局部破坏氧化线，降低冷搭的严重程度，提高静态强度。缝焊缝的疲劳性能低于最强静态条件下的疲劳性能，由于重叠的特定特征和与再入孔相关的孔隙率，短缝焊缝特别容易受到缺口效应的影响。一般来说，交叉缝焊缝的静态强度可以超过连续FSW，但疲劳优化需要减轻冷搭接和再入缺陷的严重程度，例如，通过调整工具和销的设计。

{"title":"Investigation of the weld characteristics of AA6016-T4 friction stitch welds in overlap configuration and the influence of stitch length on static and fatigue strength","authors":"Dominik Walz, Stefan Weihe, Martin Werz","doi":"10.1016/j.jajp.2025.100363","DOIUrl":"10.1016/j.jajp.2025.100363","url":null,"abstract":"<div><div>High-strength, age-hardenable aluminum alloys in car body construction challenge conventional joining methods — especially in mixed-material body structures, as fusion welding is prone to hot cracking and to hydrogen porosity. As a solid-state process, friction stir welding circumvents these challenges and typically produces joints with a higher strength than fusion welding, particularly in high-strength aluminum alloys. While friction stir spot welding guns are commercially available, the joints produced with them exhibit significantly lower strength compared to linear welds. To address this issue, a friction stir welding gun capable of producing short stitch welds was developed for a possible application in car body manufacturing.</div><div>This work investigates friction stitch welds in AA6016-T4 sheet overlap joints and quantifies how the stitch length influences static strength, fatigue performance, hardness, and microstructure, compared to a continuous friction stir welded (FSW) joint. Short stitch welds obtained the highest lap-shear strength, achieving up to 83% joint efficiency, while longer welds reached between 65% and 68%. Metallography confirmed overlap-specific features, such as cold-lap imperfections in the weld, and showed that tool reentry can locally fragment the oxide line and diminish cold-lap severity, improving static strength. The fatigue performance of the stitch welds was lower than that of the strongest static condition, with short stitches particularly susceptible to notch effects due to overlap-specific features and reentry-related porosity. In general, intersecting stitch welds can surpass continuous FSW in static strength, but fatigue optimization will require mitigating the severity of the cold lap and reentry imperfections, for example, through adapted tool and pin designs.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100363"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145614593","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}

引用次数: 0

Modeling and simulation of inertia and continuous drive friction welding of AISI 1215 steel AISI 1215钢惯性与连续驱动摩擦焊接的建模与仿真

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-12-01 DOI: 10.1016/j.jajp.2025.100360

Carina Vauderwange , Dirk Lindenau , Heinz Palkowski , Hadi Mozaffari Jovein

To accurately simulate rotary friction welding (RFW), calibration of the material model and friction conditions is essential. This study focuses on developing a material model and simulation for RFW of AISI 1215 free-machining steel in the environment “virtua RFW”. Inertia (IFW) and continuous drive friction welding (CDFW) were physically performed with comparable energy inputs to calibrate the simulation. The aim of this study is to examine the calibration procedure in detail and subsequently perform a simulation-based process comparison of IFW and CDFW. For calibration, four material and friction factors were varied in an L16 Taguchi array. Different methods for evaluating simulation quality were assessed. Upset deviation and flash angle α measurement via image processing were determined to be the most suitable methods for evaluating the alignment between simulation and real welds. Optimal simulation parameters were identified for IFW, closely matching experimental results. Due to the velocity and pressure dependence of the friction behavior, a direct transfer of parameters to CDFW was not possible, requiring adjustments and regression analysis for accurate prediction. Optimized simulations showed differences in the thermomechanical behavior: IFW exhibited a steeper temperature gradient with a minimum cooling time t8/5 of 2.5 s and a double-wedge shape in the affected zone, while CDFW showed a broader, more uniform zone with a minimum cooling time t8/5 of 3 s. These findings improve the understanding of IFW and CDFW and provide calibrated simulation models that could facilitate more efficient process development.

为了准确地模拟旋转摩擦焊接（RFW），材料模型和摩擦条件的校准至关重要。本研究的重点是建立AISI 1215自由加工钢在“虚拟RFW”环境下的材料模型和RFW仿真。惯性焊接（IFW）和连续驱动摩擦焊接（CDFW）在物理上进行了比较的能量输入，以校准模拟。本研究的目的是详细检查校准程序，并随后对IFW和CDFW进行基于模拟的过程比较。为了校准，在L16田口阵列中改变了四种材料和摩擦因素。对不同的仿真质量评价方法进行了评价。通过图像处理确定了镦粗偏差和闪光角α是评价模拟焊缝与实际焊缝对中程度的最合适方法。确定了IFW的最优仿真参数，与实验结果吻合较好。由于摩擦行为依赖于速度和压力，因此不可能将参数直接传递到CDFW，需要进行调整和回归分析才能准确预测。优化后的模拟结果显示了热力学行为的差异：IFW表现出更陡的温度梯度，最小冷却时间为2.5 s，影响区呈双楔状，而CDFW表现出更宽、更均匀的区域，最小冷却时间为3 s。这些发现提高了对IFW和CDFW的理解，并提供了校准的模拟模型，可以促进更有效的工艺开发。

{"title":"Modeling and simulation of inertia and continuous drive friction welding of AISI 1215 steel","authors":"Carina Vauderwange , Dirk Lindenau , Heinz Palkowski , Hadi Mozaffari Jovein","doi":"10.1016/j.jajp.2025.100360","DOIUrl":"10.1016/j.jajp.2025.100360","url":null,"abstract":"<div><div>To accurately simulate rotary friction welding (RFW), calibration of the material model and friction conditions is essential. This study focuses on developing a material model and simulation for RFW of AISI 1215 free-machining steel in the environment “virtua RFW”. Inertia (IFW) and continuous drive friction welding (CDFW) were physically performed with comparable energy inputs to calibrate the simulation. The aim of this study is to examine the calibration procedure in detail and subsequently perform a simulation-based process comparison of IFW and CDFW. For calibration, four material and friction factors were varied in an L16 Taguchi array. Different methods for evaluating simulation quality were assessed. Upset deviation and flash angle α measurement via image processing were determined to be the most suitable methods for evaluating the alignment between simulation and real welds. Optimal simulation parameters were identified for IFW, closely matching experimental results. Due to the velocity and pressure dependence of the friction behavior, a direct transfer of parameters to CDFW was not possible, requiring adjustments and regression analysis for accurate prediction. Optimized simulations showed differences in the thermomechanical behavior: IFW exhibited a steeper temperature gradient with a minimum cooling time t8/5 of 2.5 s and a double-wedge shape in the affected zone, while CDFW showed a broader, more uniform zone with a minimum cooling time t8/5 of 3 s. These findings improve the understanding of IFW and CDFW and provide calibrated simulation models that could facilitate more efficient process development.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100360"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145681468","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}

引用次数: 0

Material-specific beam-plume interactions during deep-penetration laser welding of stainless steel, aluminum, and copper 不锈钢、铝和铜的深熔激光焊接过程中特定材料的光束-羽流相互作用

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-11-29 DOI: 10.1016/j.jajp.2025.100366

Johannes Wahl , Christian Frey , John Powell , Michael Haas , Simon Olschok , Uwe Reisgen , Christian Hagenlocher , Thomas Graf

During deep-penetration laser welding, a hot vapor plume is emitted from the keyhole which, on cooling, condenses into a particle cloud that surrounds the weld zone. This vapor plume and associated particle cloud interact with the incident laser beam through scattering, absorption, and phase front distortion, dynamically altering the beam caustic and potentially affecting weld quality. In this study, the mechanisms governing the beam-plume interaction are investigated by observation of the thermal emission and scattered laser light from the interaction zone during the welding of stainless steel, aluminum, and copper. For this analysis, a spectrometer and a high-speed camera equipped with optical filters were used. The results revealed significant material-specific differences in thermal emission and scattered laser light from the plume, indicating variations in absorption and scattering behavior and thus beam attenuation. Re-heating of plume material until evaporation took place for all three materials. Stainless steel exhibited the strongest thermal emission, while aluminum and copper showed significantly weaker emission. In contrast, the aluminum plume displayed the highest level of laser light scattering. This is attributed to the presence of liquid and solid particles rather than purely vaporized material, even close to the laser beam focus. Distinct interaction zones within the laser beam caustic were identified, each corresponding to specific aggregate states and characteristic laser-plume interactions. For stainless steel and copper, a zone forms close to the keyhole which is primarily composed of vaporized material. Beyond this there is a multi-phase zone containing both vapor and liquid or solid matter. Further from the keyhole, a particle zone with no detectable vapor appears as re-heating becomes insufficient for evaporation. In aluminum, no distinct vapor zone was detected. Instead, strong scattering near the keyhole indicates the presence of particles even at high laser intensities. Thus, only a multi-phase and a particle zone appear to form for aluminum under the welding parameters used.

在深熔激光焊接过程中，热蒸汽羽状物从锁孔中发射出来，冷却后凝结成围绕焊接区域的粒子云。这种蒸汽羽流和相关的粒子云通过散射、吸收和相位前畸变与入射激光束相互作用，动态地改变光束的腐蚀性，并可能影响焊接质量。本文通过对不锈钢、铝和铜焊接过程中相互作用区的热发射和散射激光的观测，探讨了控制光束-羽相互作用的机制。为了进行分析，使用了一台分光计和一台装有滤光片的高速摄像机。结果显示，来自羽流的热发射和散射激光具有显著的材料特异性差异，表明吸收和散射行为的变化，从而导致光束衰减。重新加热羽流材料，直到所有三种材料都发生蒸发。不锈钢的热发射最强，铝和铜的热发射明显弱。相比之下，铝羽显示出最高水平的激光散射。这是由于液体和固体颗粒的存在，而不是纯粹的汽化物质，甚至接近激光束焦点。在激光束焦散中确定了不同的相互作用区，每个相互作用区对应于特定的聚集态和特征激光-羽相互作用。对于不锈钢和铜，在锁眼附近形成一个主要由蒸发材料组成的区域。除此之外，还有一个多相区，其中既有蒸汽，也有液体或固体物质。在钥匙孔更远的地方，由于再加热不足以蒸发，出现了一个没有可检测到蒸汽的颗粒区。在铝中，没有检测到明显的蒸汽区。相反，锁孔附近的强散射表明即使在高激光强度下也存在粒子。因此，在所使用的焊接参数下，铝只形成多相和颗粒区。

{"title":"Material-specific beam-plume interactions during deep-penetration laser welding of stainless steel, aluminum, and copper","authors":"Johannes Wahl , Christian Frey , John Powell , Michael Haas , Simon Olschok , Uwe Reisgen , Christian Hagenlocher , Thomas Graf","doi":"10.1016/j.jajp.2025.100366","DOIUrl":"10.1016/j.jajp.2025.100366","url":null,"abstract":"<div><div>During deep-penetration laser welding, a hot vapor plume is emitted from the keyhole which, on cooling, condenses into a particle cloud that surrounds the weld zone. This vapor plume and associated particle cloud interact with the incident laser beam through scattering, absorption, and phase front distortion, dynamically altering the beam caustic and potentially affecting weld quality. In this study, the mechanisms governing the beam-plume interaction are investigated by observation of the thermal emission and scattered laser light from the interaction zone during the welding of stainless steel, aluminum, and copper. For this analysis, a spectrometer and a high-speed camera equipped with optical filters were used. The results revealed significant material-specific differences in thermal emission and scattered laser light from the plume, indicating variations in absorption and scattering behavior and thus beam attenuation. Re-heating of plume material until evaporation took place for all three materials. Stainless steel exhibited the strongest thermal emission, while aluminum and copper showed significantly weaker emission. In contrast, the aluminum plume displayed the highest level of laser light scattering. This is attributed to the presence of liquid and solid particles rather than purely vaporized material, even close to the laser beam focus. Distinct interaction zones within the laser beam caustic were identified, each corresponding to specific aggregate states and characteristic laser-plume interactions. For stainless steel and copper, a zone forms close to the keyhole which is primarily composed of vaporized material. Beyond this there is a multi-phase zone containing both vapor and liquid or solid matter. Further from the keyhole, a particle zone with no detectable vapor appears as re-heating becomes insufficient for evaporation. In aluminum, no distinct vapor zone was detected. Instead, strong scattering near the keyhole indicates the presence of particles even at high laser intensities. Thus, only a multi-phase and a particle zone appear to form for aluminum under the welding parameters used.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100366"},"PeriodicalIF":4.0,"publicationDate":"2025-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145665318","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}

引用次数: 0

Influence of secondary aluminum content on casting and weldability of high pressure die cast materials for sustainable automotive body concepts 二次铝含量对可持续汽车车身概念高压压铸材料铸造和可焊性的影响

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-11-28 DOI: 10.1016/j.jajp.2025.100361

Dirk Dittrich , Dirk Lehmhus , Marco Haesche , Leonardo Fernandes Gomes , Christoph Pille , Axel Jahn , Linda Ullmann , Charlotte Graner

Sustainability is becoming increasingly important in vehicle production. The e-mobility transition has shifted the CO₂ footprint from use to production phase, where secondary aluminum alloys in structural castings are known to offer significant CO₂ reduction potential. However, accumulation of copper, iron, manganese and zinc and the hydrogen content in the melt pose major challenges for casting and subsequent joining processes. In laser welding, dynamic modulation of intensity distributions in the weld pool can overcome the latter issue. In experimental studies covering high pressure die-cast AlSi10MnMg alloys with secondary material content levels ranging from 0 wt.-% and 58 wt.-% to 89 wt.-%, castability and weldability were investigated and the structural and mechanical properties of the joint determined. The results contribute to the optimization of sustainable car body production, providing a path towards cost-effective differential lightweight design solutions as economically, technologically and ecologically competitive alternatives to large-scale casting technologies (GigaCasting).

可持续性在汽车生产中变得越来越重要。电动汽车的转型已经将二氧化碳足迹从使用阶段转移到生产阶段，而结构铸件中的二次铝合金被认为具有显著的二氧化碳减排潜力。然而，铜、铁、锰和锌的积累以及熔体中的氢含量对铸造和随后的连接工艺构成了重大挑战。在激光焊接中，动态调制熔池的强度分布可以克服后一个问题。在高压压铸AlSi10MnMg合金的实验研究中，二次材料含量从0 wt.-%到58 wt.-%到89 wt.-%，研究了浇注性和可焊性，并确定了接头的结构和机械性能。研究结果有助于优化可持续的车身生产，为实现具有成本效益的差异化轻量化设计解决方案提供了一条道路，作为大规模铸造技术（GigaCasting）在经济、技术和生态方面具有竞争力的替代品。

{"title":"Influence of secondary aluminum content on casting and weldability of high pressure die cast materials for sustainable automotive body concepts","authors":"Dirk Dittrich , Dirk Lehmhus , Marco Haesche , Leonardo Fernandes Gomes , Christoph Pille , Axel Jahn , Linda Ullmann , Charlotte Graner","doi":"10.1016/j.jajp.2025.100361","DOIUrl":"10.1016/j.jajp.2025.100361","url":null,"abstract":"<div><div>Sustainability is becoming increasingly important in vehicle production. The e-mobility transition has shifted the CO<sub>2</sub> footprint from use to production phase, where secondary aluminum alloys in structural castings are known to offer significant CO<sub>2</sub> reduction potential. However, accumulation of copper, iron, manganese and zinc and the hydrogen content in the melt pose major challenges for casting and subsequent joining processes. In laser welding, dynamic modulation of intensity distributions in the weld pool can overcome the latter issue. In experimental studies covering high pressure die-cast AlSi10MnMg alloys with secondary material content levels ranging from 0 wt.-% and 58 wt.-% to 89 wt.-%, castability and weldability were investigated and the structural and mechanical properties of the joint determined. The results contribute to the optimization of sustainable car body production, providing a path towards cost-effective differential lightweight design solutions as economically, technologically and ecologically competitive alternatives to large-scale casting technologies (GigaCasting).</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100361"},"PeriodicalIF":4.0,"publicationDate":"2025-11-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145738200","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}

引用次数: 0

Microstructure and mechanical properties of hand-held laser beam welded S700MC high-strength steel 手持式激光束焊接S700MC高强度钢的组织与力学性能

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-11-10 DOI: 10.1016/j.jajp.2025.100359

Johannes Günther , Robert Prowaznik , Daniel Krug , Simon Jahn , Thomas Niendorf , Thomas Wegener

Hand-held laser beam welding (HLBW) has gained attention due to its flexibility, high welding speeds, and excellent joint appearance. Since research on this technique remains limited, the present study provides first insights into HLBW of S700MC high-strength low-alloy steel. Radiographic analysis reveals that joints with a low degree of porosity can be achieved, addressing a major challenge of manual welding. Mechanical characterization by hardness, V-notch impact, and tensile testing demonstrates good performance of the welded structure. The welded joint exhibits a yield strength of 686 MPa and a tensile strength of 778 MPa compared to 775 MPa and 840 MPa of the base material, respectively. Hardness measurements show a reduction from 280 HV0.5 in the base material to ≤ 240 HV0.5 in the fine-grained heat-affected zone, consistent with the observed strength decrease and within the limits of the ER100S-G filler wire. Despite a reduction in fracture elongation from 20 % to ≈ 10 %, the absorbed impact energy reaches 36.5 J, exceeding the value of 30 J being characteristic for the base material, indicating sufficient ductility. Microstructural analysis reveals distinct cementite-free upper and granular bainite, acicular and polygonal ferrite as well as various morphologies of martensite-austenite constituents in the fusion zone and at given distances to the fusion line. A cooling time t_8/₅ ≈ 6 s was determined, to eventually enable quantitative process–microstructure–property correlation. Overall, the study confirms that HLBW enables the production of mechanically sound welds in S700MC, eventually allowing for robust application of this emerging technology for joining of high-strength thermo-mechanical processed mildsteel.

手持式激光束焊接（HLBW）因其灵活、焊接速度快、接头外观好等优点而受到人们的关注。由于对该技术的研究仍然有限，本研究为S700MC高强度低合金钢的HLBW提供了首次见解。射线照相分析表明，可以实现低孔隙度的接头，解决了手工焊接的主要挑战。通过硬度、v形缺口冲击和拉伸试验等力学表征表明，焊接结构具有良好的性能。与母材的775 MPa和840 MPa相比，焊接接头的屈服强度为686 MPa，抗拉强度为778 MPa。硬度测量表明，在细晶热影响区，基材的硬度从280 HV0.5降低到≤240 HV0.5，这与观察到的强度下降一致，并且在ER100S-G填充丝的极限内。尽管断裂伸长率从20%下降到约10%，但吸收的冲击能达到36.5 J，超过了母材的特征值30 J，表明具有足够的延展性。显微组织分析显示，在熔合区和距离熔合线一定距离处存在明显的无渗碳上部贝氏体和粒状贝氏体、针状铁素体和多边形铁素体，以及各种形态的马氏体-奥氏体成分。冷却时间为t1 /5≈6 s，最终实现了工艺-显微组织-性能的定量关联。总体而言，该研究证实，HLBW能够在S700MC中生产机械焊接，最终允许这种新兴技术在高强度热机械加工低碳钢连接方面的强大应用。

{"title":"Microstructure and mechanical properties of hand-held laser beam welded S700MC high-strength steel","authors":"Johannes Günther , Robert Prowaznik , Daniel Krug , Simon Jahn , Thomas Niendorf , Thomas Wegener","doi":"10.1016/j.jajp.2025.100359","DOIUrl":"10.1016/j.jajp.2025.100359","url":null,"abstract":"<div><div>Hand-held laser beam welding (HLBW) has gained attention due to its flexibility, high welding speeds, and excellent joint appearance. Since research on this technique remains limited, the present study provides first insights into HLBW of S700MC high-strength low-alloy steel. Radiographic analysis reveals that joints with a low degree of porosity can be achieved, addressing a major challenge of manual welding. Mechanical characterization by hardness, V-notch impact, and tensile testing demonstrates good performance of the welded structure. The welded joint exhibits a yield strength of 686 MPa and a tensile strength of 778 MPa compared to 775 MPa and 840 MPa of the base material, respectively. Hardness measurements show a reduction from 280 HV0.5 in the base material to ≤ 240 HV0.5 in the fine-grained heat-affected zone, consistent with the observed strength decrease and within the limits of the ER100S-G filler wire. Despite a reduction in fracture elongation from 20 % to ≈ 10 %, the absorbed impact energy reaches 36.5 J, exceeding the value of 30 J being characteristic for the base material, indicating sufficient ductility. Microstructural analysis reveals distinct cementite-free upper and granular bainite, acicular and polygonal ferrite as well as various morphologies of martensite-austenite constituents in the fusion zone and at given distances to the fusion line. A cooling time t<sub>8/</sub><sub>5</sub> ≈ 6 s was determined, to eventually enable quantitative process–microstructure–property correlation. Overall, the study confirms that HLBW enables the production of mechanically sound welds in S700MC, eventually allowing for robust application of this emerging technology for joining of high-strength thermo-mechanical processed mildsteel.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100359"},"PeriodicalIF":4.0,"publicationDate":"2025-11-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145568213","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}

引用次数: 0

Effects of adjustable ring mode laser-beam control on microstructure and mechanical properties of AA6N01-T5 aluminum alloy in laser-arc hybrid welding 可调环模激光束控制对AA6N01-T5铝合金激光电弧复合焊接组织和力学性能的影响

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-11-08 DOI: 10.1016/j.jajp.2025.100358

Seonghyun Kim , Hyun-Uk Jun , Jooyong Cheon , Gyuheun Lee , Changwook Ji , Yang-Do Kim

This study evaluated the effects of beam control in adjustable ring mode laser-arc hybrid welding on the microstructure, porosity, and mechanical properties of a 5-mm-thick AA6N01-T5 Al alloy. Three laser-beam conditions—ring-beam hybrid welding (RBHW), center-beam hybrid welding (CBHW), and dual-beam hybrid welding (DBHW)—were compared under similar heat input conditions. The factors with the most significant influence on the mechanical properties in the welding of the AA6N01-T5 Al alloy are the porosity, grain size, and presence of strengthening precipitates. The weld porosity was quantified via high-resolution X-ray three-dimensional computed tomography, the grain structure was characterized via electron backscatter diffraction, the distribution and content of Mg—a key element in precipitation strengthening—were examined via electron probe microanalysis, and tensile and microhardness tests were performed in compliance with ASTM standards. RBHW achieved the lowest porosity (0.77 %) and the highest elongation (8.7 %) owing to the stable keyhole geometry and enhanced molten-pool convection. DBHW exhibited the smallest equiaxed grain size (179.43 μm) and the lowest Mg loss (0.89 wt%), resulting in the highest tensile (178.9 MPa) and yield (121.8 MPa) strengths. CBHW exhibited a combination of high porosity, coarse grains, and severe Mg loss, which degraded the mechanical performance of the weld. These findings clarify that the laser-beam energy distribution influences the molten-pool behavior, microstructure, and mechanical properties of the weld, thereby affecting the performance and reliability of high-strength Al alloy welds in lightweight manufacturing applications.

研究了可调环模激光电弧复合焊接中光束控制对5 mm厚AA6N01-T5铝合金显微组织、孔隙率和力学性能的影响。在相似的热输入条件下，比较了三种激光束条件——环束混合焊接（RBHW）、中心束混合焊接（CBHW）和双束混合焊接（DBHW）。对AA6N01-T5铝合金焊接力学性能影响最大的因素是气孔率、晶粒尺寸和强化相的存在。采用高分辨率x射线三维计算机断层扫描对焊缝孔隙率进行量化，采用电子背散射衍射对晶粒结构进行表征，采用电子探针显微分析检测析出强化关键元素mg的分布和含量，并按照ASTM标准进行拉伸和显微硬度测试。RBHW的孔隙率最低（0.77%），伸长率最高（8.7%），这是由于稳定的锁孔几何形状和增强的熔池对流。DBHW的等轴晶粒尺寸最小（179.43 μm）， Mg损失最小（0.89 wt%），拉伸强度和屈服强度分别为178.9 MPa和121.8 MPa。CBHW表现为高孔隙率、粗晶粒和严重的Mg损失，从而降低了焊缝的力学性能。这些发现表明，激光束能量分布会影响熔池行为、显微组织和焊缝的力学性能，从而影响轻量化制造应用中高强度铝合金焊缝的性能和可靠性。

{"title":"Effects of adjustable ring mode laser-beam control on microstructure and mechanical properties of AA6N01-T5 aluminum alloy in laser-arc hybrid welding","authors":"Seonghyun Kim , Hyun-Uk Jun , Jooyong Cheon , Gyuheun Lee , Changwook Ji , Yang-Do Kim","doi":"10.1016/j.jajp.2025.100358","DOIUrl":"10.1016/j.jajp.2025.100358","url":null,"abstract":"<div><div>This study evaluated the effects of beam control in adjustable ring mode laser-arc hybrid welding on the microstructure, porosity, and mechanical properties of a 5-mm-thick AA6N01-T5 Al alloy. Three laser-beam conditions—ring-beam hybrid welding (RBHW), center-beam hybrid welding (CBHW), and dual-beam hybrid welding (DBHW)—were compared under similar heat input conditions. The factors with the most significant influence on the mechanical properties in the welding of the AA6N01-T5 Al alloy are the porosity, grain size, and presence of strengthening precipitates. The weld porosity was quantified via high-resolution X-ray three-dimensional computed tomography, the grain structure was characterized via electron backscatter diffraction, the distribution and content of Mg—a key element in precipitation strengthening—were examined via electron probe microanalysis, and tensile and microhardness tests were performed in compliance with ASTM <span><span>standards</span><svg><path></path></svg></span>. RBHW achieved the lowest porosity (0.77 %) and the highest elongation (8.7 %) owing to the stable keyhole geometry and enhanced molten-pool convection. DBHW exhibited the smallest equiaxed grain size (179.43 μm) and the lowest Mg loss (0.89 wt%), resulting in the highest tensile (178.9 MPa) and yield (121.8 MPa) strengths. CBHW exhibited a combination of high porosity, coarse grains, and severe Mg loss, which degraded the mechanical performance of the weld. These findings clarify that the laser-beam energy distribution influences the molten-pool behavior, microstructure, and mechanical properties of the weld, thereby affecting the performance and reliability of high-strength Al alloy welds in lightweight manufacturing applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100358"},"PeriodicalIF":4.0,"publicationDate":"2025-11-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145519439","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}

引用次数: 0

Effect of tool material on joint quality in friction stir welding of aluminum-steel tailor welded blanks 工具材料对铝-钢拼焊板搅拌摩擦焊接头质量的影响

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-11-08 DOI: 10.1016/j.jajp.2025.100355

Robin Göbel, Maximilian Keppler, Stefan Weihe, Martin Werz

Friction stir welding (FSW) enables high-strength joints between dissimilar materials such as aluminum and steel and is particularly suited for hybrid tailor welded blanks in deep drawing. A special joining configuration, developed at the Material Testing Institute in Stuttgart, allows joining a high-strength aluminum alloy to thinner steel in a combined butt and overlap joint. Despite its proven advantages, this welding process shows inconsistent outcomes regarding formability and joint strength. This research examines the influence of tool material on weld quality and process robustness. H13 steel, ceramics (Si

_{3}

N

_{4}

and SiAlON) and TiAlN-coated tungsten carbide tools were evaluated in welds joining 1 mm steel to 2 mm aluminum sheets. Material accumulation was quantified by 3D scanning and continuous weighing. Weld seam integrity was assessed by X-ray imaging, metallography and tensile testing with regard to aluminum-steel intermixing. The findings show that during friction stir welding of aluminum and steel in a combined butt and overlap joint, both steel and ceramic tools predominantly degrade through the adhesion of workpiece material. The H13 tool exhibits steel/aluminum buildup detaching after 1.5-2.5 m, altering geometry and intermixing. Fluctuations in material accretion lead to varying process conditions over successive welds or even within one weld. By contrast, the TiAlN-coated WC tool exhibits significantly less buildup and therefore more uniform weld seam quality. Moreover, a relatively high degree of aluminum-steel intermixing consistently correlates with superior weld strength and formability. The study highlights how tool degradation and intermixing affect weld quality and emphasizes the role of tool materials for robust industrial applications.

搅拌摩擦焊（FSW）可以实现不同材料（如铝和钢）之间的高强度连接，特别适用于深拉深的混合定制焊接坯料。斯图加特的材料测试研究所开发了一种特殊的连接配置，可以将高强度铝合金连接到较薄的钢中，形成组合对接和重叠连接。尽管其优点已被证明，但这种焊接工艺在成形性和接头强度方面表现出不一致的结果。本研究考察了刀具材料对焊接质量和工艺稳健性的影响。对H13钢、陶瓷（Si3N4和SiAlON）和tialn涂层碳化钨工具在连接1mm钢和2mm铝板的焊接中进行了评估。通过三维扫描和连续称重来量化物质堆积。采用x射线成像、金相分析和拉伸试验对铝-钢混合焊缝的完整性进行了评定。结果表明，在铝与钢混合对接和重叠接头搅拌摩擦焊接过程中，钢和陶瓷刀具主要通过与工件材料的粘附而降解。H13刀具在1.5-2.5 m处表现出钢/铝组合物分离，改变几何形状和混合。在连续的焊接中，甚至在一个焊接中，材料增加的波动导致不同的工艺条件。相比之下，镀有tialn的WC工具显示出更少的堆积，因此焊缝质量更均匀。此外，较高程度的铝-钢混合始终与优异的焊接强度和成形性相关。该研究强调了刀具退化和混合如何影响焊接质量，并强调了刀具材料在强大的工业应用中的作用。

{"title":"Effect of tool material on joint quality in friction stir welding of aluminum-steel tailor welded blanks","authors":"Robin Göbel, Maximilian Keppler, Stefan Weihe, Martin Werz","doi":"10.1016/j.jajp.2025.100355","DOIUrl":"10.1016/j.jajp.2025.100355","url":null,"abstract":"<div><div>Friction stir welding (FSW) enables high-strength joints between dissimilar materials such as aluminum and steel and is particularly suited for hybrid tailor welded blanks in deep drawing. A special joining configuration, developed at the Material Testing Institute in Stuttgart, allows joining a high-strength aluminum alloy to thinner steel in a combined butt and overlap joint. Despite its proven advantages, this welding process shows inconsistent outcomes regarding formability and joint strength. This research examines the influence of tool material on weld quality and process robustness. H13 steel, ceramics (Si<span><math><msub><mrow></mrow><mrow><mn>3</mn></mrow></msub></math></span>N<span><math><msub><mrow></mrow><mrow><mn>4</mn></mrow></msub></math></span> and SiAlON) and TiAlN-coated tungsten carbide tools were evaluated in welds joining 1 mm steel to 2 mm aluminum sheets. Material accumulation was quantified by 3D scanning and continuous weighing. Weld seam integrity was assessed by X-ray imaging, metallography and tensile testing with regard to aluminum-steel intermixing. The findings show that during friction stir welding of aluminum and steel in a combined butt and overlap joint, both steel and ceramic tools predominantly degrade through the adhesion of workpiece material. The H13 tool exhibits steel/aluminum buildup detaching after 1.5-2.5 m, altering geometry and intermixing. Fluctuations in material accretion lead to varying process conditions over successive welds or even within one weld. By contrast, the TiAlN-coated WC tool exhibits significantly less buildup and therefore more uniform weld seam quality. Moreover, a relatively high degree of aluminum-steel intermixing consistently correlates with superior weld strength and formability. The study highlights how tool degradation and intermixing affect weld quality and emphasizes the role of tool materials for robust industrial applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100355"},"PeriodicalIF":4.0,"publicationDate":"2025-11-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145519440","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}

引用次数: 0

Investigation of microstructural and mechanical properties of dissimilar WC–8 %Co/AISI 1006 steel joints brazed using tube, induction, and infrared furnaces 不同wc - 8% Co/AISI 1006钢钎焊接头的显微组织和力学性能研究

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-11-05 DOI: 10.1016/j.jajp.2025.100357

Amin Shafinejad Bejandi, Hamid Khorsand, Mehdi Moslemi, Ali Ostad Akbarian Azar

Integrating tungsten carbide (WC–8Co) with steel is a pivotal aspect of cutting tool manufacturing, as monolithic carbide tools are inherently brittle and cannot be fabricated as a single component. To enhance toughness and resistance to dynamic stresses, WC is brazed to steels with greater ductility. Given WC's high melting temperature, conventional welding methods are ineffective, making brazing one of the most suitable techniques for joining dissimilar materials. This study aimed to optimize the brazing process to minimize the loss of WC hardness, as a reduction in hardness compromises tool efficiency and lifespan. In this research, WC–8Co was brazed to AISI 1006 steel using a silver-based filler (BAg22) through tube, induction, and infrared furnaces at temperatures of 800 °C, 850 °C, and 900 °C under vacuum conditions, with induction powers set at 10 and 15 kW. The microstructural and mechanical properties were assessed using scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), microhardness testing, and shear testing. The initial hardness of WC was measured at 2202 HV, with decreases of 1.8%, 10%, and 22% observed for the induction, infrared, and tube furnaces, respectively. The shear strength was highest for the induction furnace (294 MPa), followed by the infrared furnace (268 MPa) and the tube furnace (202 MPa). OM/SEM/EDS analyses revealed a silver- and copper-rich eutectic structure, while elevated temperatures enhanced filler wettability and diffusion, resulting in uniform, defect-free joints. These findings yield quantitative insights for optimizing the brazing of WC–steel joints, facilitating the manufacturing of high-performance cutting tools.

将碳化钨（WC-8Co）与钢结合是切削刀具制造的关键方面，因为整体碳化钨刀具本身就很脆，不能作为单一部件制造。为了提高韧性和抗动应力，WC被钎焊到具有更大延展性的钢上。由于WC的熔化温度高，传统的焊接方法是无效的，因此钎焊是连接异种材料的最合适的技术之一。本研究旨在优化钎焊工艺，以尽量减少WC硬度的损失，因为硬度的降低会影响工具的效率和寿命。在本研究中，采用银基填料（BAg22）将WC-8Co钎焊到AISI 1006钢上，在真空条件下，分别在800°C、850°C和900°C的感应炉、感应功率分别为10和15 kW。采用扫描电镜（SEM）、能谱仪（EDS）、显微硬度测试和剪切测试对材料的显微组织和力学性能进行了评估。在2202 HV时测得WC的初始硬度，感应炉、红外炉和管式炉分别下降1.8%、10%和22%。感应炉的抗剪强度最高（294 MPa），其次是红外炉（268 MPa）和管式炉（202 MPa）。OM/SEM/EDS分析揭示了富银和富铜的共晶结构，而高温增强了填料的润湿性和扩散，形成了均匀、无缺陷的接头。这些发现为优化wc -钢接头的钎焊提供了定量见解，促进了高性能切削工具的制造。

{"title":"Investigation of microstructural and mechanical properties of dissimilar WC–8 %Co/AISI 1006 steel joints brazed using tube, induction, and infrared furnaces","authors":"Amin Shafinejad Bejandi, Hamid Khorsand, Mehdi Moslemi, Ali Ostad Akbarian Azar","doi":"10.1016/j.jajp.2025.100357","DOIUrl":"10.1016/j.jajp.2025.100357","url":null,"abstract":"<div><div>Integrating tungsten carbide (WC–8Co) with steel is a pivotal aspect of cutting tool manufacturing, as monolithic carbide tools are inherently brittle and cannot be fabricated as a single component. To enhance toughness and resistance to dynamic stresses, WC is brazed to steels with greater ductility. Given WC's high melting temperature, conventional welding methods are ineffective, making brazing one of the most suitable techniques for joining dissimilar materials. This study aimed to optimize the brazing process to minimize the loss of WC hardness, as a reduction in hardness compromises tool efficiency and lifespan. In this research, WC–8Co was brazed to AISI 1006 steel using a silver-based filler (BAg22) through tube, induction, and infrared furnaces at temperatures of 800 °C, 850 °C, and 900 °C under vacuum conditions, with induction powers set at 10 and 15 kW. The microstructural and mechanical properties were assessed using scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), microhardness testing, and shear testing. The initial hardness of WC was measured at 2202 HV, with decreases of 1.8%, 10%, and 22% observed for the induction, infrared, and tube furnaces, respectively. The shear strength was highest for the induction furnace (294 MPa), followed by the infrared furnace (268 MPa) and the tube furnace (202 MPa). OM/SEM/EDS analyses revealed a silver- and copper-rich eutectic structure, while elevated temperatures enhanced filler wettability and diffusion, resulting in uniform, defect-free joints. These findings yield quantitative insights for optimizing the brazing of WC–steel joints, facilitating the manufacturing of high-performance cutting tools.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100357"},"PeriodicalIF":4.0,"publicationDate":"2025-11-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145738199","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}

引用次数: 0