Journal of Advanced Joining Processes最新文献_第3页

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

Mechanical properties of intermetallic compounds at solder joint interfaces investigated using nanoindentation technique 利用纳米压痕技术研究了焊点界面金属间化合物的力学性能

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-10-27 DOI: 10.1016/j.jajp.2025.100356

Wei-Rong Yang , Kiyokazu Yasuda , Jenn-Ming Song

Nanoindentation technique is applied as the key tool to investigated mechanical properties of intermetallic compounds, particularly those formed at solder joint interfaces, which are essential for the mechanical stability and reliability of electronic packaging. This article reviews the findings on mechanical properties of various intermetallic compounds using nanoindentation, including the dependences of crystal orientation and structure, alloying effects, and how these influence hardness, Young’s modulus, plastic ability, and creep resistance. Young’s modulus/hardness ratio was proposed to evaluate toughness, and creep resistance, and to predict reliability of the joints. The reviews shed a brand-new approach for the alloy/substrate material design enhancing interconnect durability.

纳米压痕技术是研究金属间化合物力学性能的关键工具，特别是在焊点界面处形成的金属间化合物，对电子封装的机械稳定性和可靠性至关重要。本文综述了利用纳米压痕对各种金属间化合物的力学性能的研究结果，包括晶体取向和结构的依赖性，合金效应，以及这些因素如何影响硬度，杨氏模量，塑性能力和抗蠕变能力。采用杨氏模量/硬度比来评价接头的韧性和抗蠕变性能，并预测接头的可靠性。这些综述为合金/衬底材料设计提供了一种全新的方法，可以提高互连的耐久性。

引用次数: 0

Exploring the hybridization of wire-arc additive manufacturing and resistance spot welding 探索线弧增材制造与电阻点焊的融合

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-10-10 DOI: 10.1016/j.jajp.2025.100354

Maria R.F. Barros , Pedro M.S. Rosado , Rui F.V. Sampaio , João P.M. Pragana , Ivo M.F. Bragança , Carlos M.A. Silva , Paulo A.F. Martins

This paper explores a new hybrid manufacturing approach that combines wire-arc additive manufacturing (WAAM) with resistance spot welding (RSW). The approach integrates additively deposited materials with commercial sheets, which can serve as either supporting or functional elements. Experimental testing and finite element modelling allowed defining the weld lobe and optimizing key parameters such as electric current and welding time. Optimization was based on nugget shape, microstructure, and mechanical performance from destructive shear and peel tests. Two distinct joining modes were identified: symmetric and asymmetric weld nuggets, with the former exhibiting higher strength but requiring a higher heat input. A proof-of-concept prototype was developed to demonstrate the potential of this innovative hybrid manufacturing approach, combining WAAM, machining, forming, and RSW to fabricate complex, multi-thickness components with improved structural integrity.

本文探讨了一种将线弧增材制造（WAAM）与电阻点焊（RSW）相结合的新型混合制造方法。该方法将添加剂沉积材料与商业板材相结合，既可以作为支撑元素，也可以作为功能元素。通过实验测试和有限元建模，确定了焊缝瓣形，并优化了电流和焊接时间等关键参数。优化基于核块形状、微观结构以及破坏性剪切和剥离试验的力学性能。确定了两种不同的连接模式：对称和非对称焊块，前者具有更高的强度，但需要更高的热量输入。开发了一个概念验证原型，以展示这种创新的混合制造方法的潜力，将WAAM、加工、成形和RSW结合起来，制造复杂的、多厚度的部件，并提高结构完整性。

引用次数: 0

Induction kinetic welding (IKW): An innovative one-shot solid-state technique for circular joints 感应动态焊接（IKW）：一种创新的一次性固态焊接技术

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-10-01 DOI: 10.1016/j.jajp.2025.100353

Farzad Khodabakhshi, Mark Turezki, Adrian P. Gerlich

In this research, an innovative solid-state joining technology has been introduced for butt-welding of circular sections with dissimilar tube and rod geometries, using induction kinetic welding (IKW). This process involves using induction to preheat material before bringing the pieces together, where rapid heating to below the base metal melting temperature followed quickly by applying axial force and shear rotation at the joint interface. A homogeneous weld microstructure consisting of refined grains and minimal heat affected zone (HAZ) is formed at the contact interface. The present work demonstrates this for a specific application involving a circular plug (with a diameter of ∼13 mm) and thin-walled tube (with a diameter of ∼13.4 mm and a wall thickness of ∼0.35 mm) both consisting of Zircaloy-4. Among the IKW processing parameters, the influence of preheating temperature and rotational shear displacement angle are the most critical inputs examined. The final joint stress distribution near the peak fracture load was modelled using finite element analysis (FEA). To this end, induction heating up to the temperature of ∼1400°C followed by a frictional shear-rotation angle of 60-degrees achieved formation of a sound solid-state weld with upset and removal of oxides from the contact interface. Afterward, the microstructural characteristics across the welding line and mechanical properties of the produced weldments were examined. A joining efficiency of 100% was achieved during the tensile fracture of the tube/plug weldment where fracture of the tube base metal has been achieved.

在这项研究中，引入了一种创新的固态连接技术，用于使用感应动力焊接（IKW）对焊具有不同管和棒几何形状的圆形截面。该工艺包括在将零件组合在一起之前使用感应预热材料，其中快速加热到低于母材熔化温度，然后在接合界面快速施加轴向力和剪切旋转。在接触界面处形成细小晶粒和最小热影响区（HAZ）的均匀焊缝组织。目前的工作在涉及圆形塞（直径约13毫米）和薄壁管（直径约13.4毫米，壁厚约0.35毫米）的特定应用中证明了这一点，两者都由锆合金-4组成。在IKW工艺参数中，预热温度和旋转剪切位移角的影响是最关键的输入。采用有限元方法模拟了峰值断裂载荷附近的最终节点应力分布。为此，感应加热至~ 1400°C的温度，然后进行60度的摩擦剪切旋转角，形成了良好的固态焊缝，并从接触界面上去除了氧化物。随后，对焊缝的显微组织特征和力学性能进行了检测。在管/塞焊件的拉伸断裂过程中，实现了100%的连接效率，其中管母金属已经断裂。

{"title":"Induction kinetic welding (IKW): An innovative one-shot solid-state technique for circular joints","authors":"Farzad Khodabakhshi, Mark Turezki, Adrian P. Gerlich","doi":"10.1016/j.jajp.2025.100353","DOIUrl":"10.1016/j.jajp.2025.100353","url":null,"abstract":"<div><div>In this research, an innovative solid-state joining technology has been introduced for butt-welding of circular sections with dissimilar tube and rod geometries, using induction kinetic welding (IKW). This process involves using induction to preheat material before bringing the pieces together, where rapid heating to below the base metal melting temperature followed quickly by applying axial force and shear rotation at the joint interface. A homogeneous weld microstructure consisting of refined grains and minimal heat affected zone (HAZ) is formed at the contact interface. The present work demonstrates this for a specific application involving a circular plug (with a diameter of ∼13 mm) and thin-walled tube (with a diameter of ∼13.4 mm and a wall thickness of ∼0.35 mm) both consisting of Zircaloy-4. Among the IKW processing parameters, the influence of preheating temperature and rotational shear displacement angle are the most critical inputs examined. The final joint stress distribution near the peak fracture load was modelled using finite element analysis (FEA). To this end, induction heating up to the temperature of ∼1400°C followed by a frictional shear-rotation angle of 60-degrees achieved formation of a sound solid-state weld with upset and removal of oxides from the contact interface. Afterward, the microstructural characteristics across the welding line and mechanical properties of the produced weldments were examined. A joining efficiency of 100% was achieved during the tensile fracture of the tube/plug weldment where fracture of the tube base metal has been achieved.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100353"},"PeriodicalIF":4.0,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145219396","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

Tailoring microstructure and interface integrity in Ti–316L dissimilar keyhole laser welding using controlled 3d magnetic field stimulation 利用可控三维磁场刺激调整Ti-316L异种锁孔激光焊接的微观结构和界面完整性

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-09-30 DOI: 10.1016/j.jajp.2025.100352

Pinku Yadav , Simone Gervasoni , David Sargent , Patrik Hoffmann , Sergey Shevchik

This study investigates the influence of externally applied magnetic fields—both alternating and rotating—on the microstructural evolution and interface integrity of laser-welded dissimilar joints between titanium and 316 L stainless steel. A fiber laser system was employed to perform keyhole-mode lap welding, with various magnetic field orientations introduced to actively manipulate the melt pool dynamics. Alternating fields (Bx, By, Bz) promoted grain refinement (reducing average grain size from 51.8 ± 4.1 µm to 36.2 ± 3.1 µm) and enhanced recrystallization (increasing the recrystallized fraction to ∼0.69), resulting in a finer microstructure and more discrete intermetallic compound (IMC) formation at the Ti–316 L interface. In contrast, rotating magnetic fields (Bxy, Byz, Bxz) encouraged coarser grain growth (increasing average grain size up to 80.1 ± 4.5 µm) and increased the presence of unrecrystallized regions (up to 0.484 fraction) due to stabilized melt flow and slower cooling rates. These conditions facilitated deeper interdiffusion and led to thicker, more continuous IMC layers, correlating with a peak microhardness of 576 ± 8 HV, potentially compromising joint integrity. The findings demonstrate that precise control of magnetic field configuration during laser processing offers a powerful tool to tailor interfacial microstructures and minimize brittle phase formation. This approach provides new opportunities to enhance the performance and reliability of dissimilar metal joints in critical structural applications.

研究了外加磁场（交变磁场和旋转磁场）对钛与316l不锈钢异种激光焊接接头显微组织演变和界面完整性的影响。采用光纤激光系统进行锁孔模式搭接焊接，并引入不同的磁场方向来主动控制熔池动力学。交替场（Bx, By, Bz）促进了晶粒细化（平均晶粒尺寸从51.8±4.1µm减小到36.2±3.1µm）和再结晶（再结晶分数增加到~ 0.69），导致ti - 316l界面处的微观结构更精细和更离散的金属间化合物（IMC）形成。相比之下，旋转磁场（Bxy, Byz, Bxz）促进了更粗的晶粒生长（平均晶粒尺寸增加到80.1±4.5µm），并且由于稳定的熔体流动和较慢的冷却速率，增加了未再结晶区域的存在（高达0.484分数）。这些条件促进了更深的相互扩散，导致更厚、更连续的IMC层，峰值显微硬度为576±8 HV，可能会损害接头的完整性。研究结果表明，在激光加工过程中精确控制磁场配置为定制界面微观结构和减少脆性相形成提供了有力的工具。这种方法为在关键结构应用中提高异种金属接头的性能和可靠性提供了新的机会。

{"title":"Tailoring microstructure and interface integrity in Ti–316L dissimilar keyhole laser welding using controlled 3d magnetic field stimulation","authors":"Pinku Yadav , Simone Gervasoni , David Sargent , Patrik Hoffmann , Sergey Shevchik","doi":"10.1016/j.jajp.2025.100352","DOIUrl":"10.1016/j.jajp.2025.100352","url":null,"abstract":"<div><div>This study investigates the influence of externally applied magnetic fields—both alternating and rotating—on the microstructural evolution and interface integrity of laser-welded dissimilar joints between titanium and 316 L stainless steel. A fiber laser system was employed to perform keyhole-mode lap welding, with various magnetic field orientations introduced to actively manipulate the melt pool dynamics. Alternating fields (Bx, By, Bz) promoted grain refinement (reducing average grain size from 51.8 ± 4.1 µm to 36.2 ± 3.1 µm) and enhanced recrystallization (increasing the recrystallized fraction to ∼0.69), resulting in a finer microstructure and more discrete intermetallic compound (IMC) formation at the Ti–316 L interface. In contrast, rotating magnetic fields (Bxy, Byz, Bxz) encouraged coarser grain growth (increasing average grain size up to 80.1 ± 4.5 µm) and increased the presence of unrecrystallized regions (up to 0.484 fraction) due to stabilized melt flow and slower cooling rates. These conditions facilitated deeper interdiffusion and led to thicker, more continuous IMC layers, correlating with a peak microhardness of 576 ± 8 HV, potentially compromising joint integrity. The findings demonstrate that precise control of magnetic field configuration during laser processing offers a powerful tool to tailor interfacial microstructures and minimize brittle phase formation. This approach provides new opportunities to enhance the performance and reliability of dissimilar metal joints in critical structural applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100352"},"PeriodicalIF":4.0,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145219387","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

Multi-objective optimization of welding-induced residual stress and deflection in 6082-T6 aluminum alloy using validated thermo-mechanical modeling 基于验证热力学模型的6082-T6铝合金焊接残余应力和挠度多目标优化

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-09-23 DOI: 10.1016/j.jajp.2025.100351

Hamidreza Rohani Raftar , Amir Khodabakhshi , Tomi Suikkari , Antti Ahola , Tuomas Skriko

Welding of aluminum alloys often introduces residual stress and deflection, compromising dimensional precision and structural performance. This study investigates the influence of key process parameters of gas metal arc welding on the thermo-mechanical response of 6082-T6 aluminum alloy butt joints. A numerical method was developed and validated using experimental measurements of temperature distribution (thermocouples), deflection (3D laser scanning), and residual stress(X-ray diffraction). A full-factorial design of experiments (DOE) was conducted, varying clamping configuration, plate thickness, welding sequence, and cooling conditions. Analysis of variance (ANOVA) quantified main and interaction effects. The study identified a trade-off between deflection and residual stress, which was addressed through multi-objective optimization using a desirability function approach. Deflection was reduced from 1.44 mm (measured experimentally) to 0.6 mm under optimized conditions, while the minimum residual stress was 171 MPa, representing a decrease of approximately 12%. The optimum condition corresponded to a partially restrained clamping configuration, a plate thickness of 4 mm, a continuous single pass welding sequence, and natural air cooling. Predictive models based on ensemble regression techniques were constructed using the 72 DOE-based FEM cases and validated with experimental measurements to estimate responses and rank influential parameters. The models achieved an R² values of 0.93 for deflection and an R² value of 0.94 for residual stress. Consistency between statistical and predictive analyses confirmed the dominant factors. The optimization framework offers a data-driven approach to improve welded structural integrity and highlights the potential of integrated simulation and data analysis in materials processing and design.

铝合金焊接常产生残余应力和变形，影响尺寸精度和结构性能。研究了气体保护金属弧焊关键工艺参数对6082-T6铝合金对接接头热-力学响应的影响。利用温度分布（热电偶）、偏转（3D激光扫描）和残余应力（x射线衍射）的实验测量，开发了一种数值方法并进行了验证。实验（DOE）的全因子设计进行了不同的夹紧配置，板的厚度，焊接顺序和冷却条件。方差分析（ANOVA）量化了主效应和交互效应。该研究确定了挠度和残余应力之间的权衡，并通过使用可取函数方法进行多目标优化。在优化条件下，挠度从1.44 mm（实验测量）减少到0.6 mm，最小残余应力为171 MPa，降低了约12%。最佳条件对应于部分受限夹紧配置，板厚为4mm，连续单道焊接顺序和自然空气冷却。利用72个基于doe的FEM案例构建了基于集合回归技术的预测模型，并通过实验测量进行验证，以估计响应并对影响参数进行排序。模型得到的挠度R²值为0.93，残余应力R²值为0.94。统计分析和预测分析之间的一致性证实了主导因素。优化框架提供了一种数据驱动的方法来提高焊接结构的完整性，并突出了材料加工和设计中集成模拟和数据分析的潜力。

{"title":"Multi-objective optimization of welding-induced residual stress and deflection in 6082-T6 aluminum alloy using validated thermo-mechanical modeling","authors":"Hamidreza Rohani Raftar , Amir Khodabakhshi , Tomi Suikkari , Antti Ahola , Tuomas Skriko","doi":"10.1016/j.jajp.2025.100351","DOIUrl":"10.1016/j.jajp.2025.100351","url":null,"abstract":"<div><div>Welding of aluminum alloys often introduces residual stress and deflection, compromising dimensional precision and structural performance. This study investigates the influence of key process parameters of gas metal arc welding on the thermo-mechanical response of 6082-T6 aluminum alloy butt joints. A numerical method was developed and validated using experimental measurements of temperature distribution (thermocouples), deflection (3D laser scanning), and residual stress(X-ray diffraction). A full-factorial design of experiments (DOE) was conducted, varying clamping configuration, plate thickness, welding sequence, and cooling conditions. Analysis of variance (ANOVA) quantified main and interaction effects. The study identified a trade-off between deflection and residual stress, which was addressed through multi-objective optimization using a desirability function approach. Deflection was reduced from 1.44 mm (measured experimentally) to 0.6 mm under optimized conditions, while the minimum residual stress was 171 MPa, representing a decrease of approximately 12%. The optimum condition corresponded to a partially restrained clamping configuration, a plate thickness of 4 mm, a continuous single pass welding sequence, and natural air cooling. Predictive models based on ensemble regression techniques were constructed using the 72 DOE-based FEM cases and validated with experimental measurements to estimate responses and rank influential parameters. The models achieved an R² values of 0.93 for deflection and an R² value of 0.94 for residual stress. Consistency between statistical and predictive analyses confirmed the dominant factors. The optimization framework offers a data-driven approach to improve welded structural integrity and highlights the potential of integrated simulation and data analysis in materials processing and design.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100351"},"PeriodicalIF":4.0,"publicationDate":"2025-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145219494","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

Electron beam welding parameters for copper and dissimilar copper joints: Review, research gaps, and future challenges 铜和异种铜接头的电子束焊接参数：回顾、研究空白和未来挑战

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-09-17 DOI: 10.1016/j.jajp.2025.100350

Sathishkumar Duraisamy , Ana Horovistiz , Antonio Bastos , Bernardo Mascate , João M.S. Dias

Copper welding presents significant challenges due to its high thermal conductivity and reflectivity, making traditional welding methods largely ineffective. Electron Beam Welding (EBW) offers a promising solution but requires precise parameter control to achieve optimal results. This study is a systematic review following a structured search of Scopus and Web of Science. After title–abstract–full text screening using predefined inclusion criteria (experimental EBW of copper or copper–dissimilar joints reporting process parameters and weld performance), 163 peer-reviewed articles were retained. For each study, the authors extracted process parameters (accelerating voltage, beam current, welding speed, focus/defocus, beam oscillation), material characteristics (alloy type, thickness, surface preparation), and outcomes (penetration, porosity, microstructure, mechanical properties). Reported statistical measures were consolidated to quantify the dominant influences of the parameters, and a SWOT analysis, along with a research gap analysis, was performed. Research indicates that vacuum-based EBW effectively overcomes copper welding difficulties while producing superior joint quality compared to other fusion processes. EBW achieves deep weld penetrations of up to 30 mm with minimal defects in copper, producing joint strengths of up to 264 MPa, equivalent to approximately 95% of the base material strength. Key welding parameters, including beam current, welding speed, focus position, and oscillation patterns, significantly influence weld quality, with beam current exerting the strongest effect on penetration depth. When joining copper to different materials, careful beam positioning and oscillation techniques successfully control unwanted compound formation while maintaining joint strength. Key findings establish that beam current accounts for 81% of the variance in weld quality control; strategic beam positioning with 0.4–0.5 mm offsets optimizes dissimilar joints, achieving strengths of 250 MPa; oscillation patterns reduce porosity by 30% while controlling intermetallic formation; and significant research gaps remain in copper tube joining applications for thermal management systems. This framework enables precision joining of high-performance copper systems for next-generation energy and electronics applications.

由于铜的高导热性和反射率，传统的焊接方法在很大程度上是无效的，因此铜焊接面临着巨大的挑战。电子束焊接（EBW）提供了一个很有前途的解决方案，但需要精确的参数控制以达到最佳效果。本研究是对Scopus和Web of Science进行结构化搜索后的系统综述。在使用预先定义的纳入标准（铜或铜异种接头的实验EBW报告工艺参数和焊接性能）对标题-摘要-全文进行筛选后，保留了163篇同行评审的文章。对于每项研究，作者提取了工艺参数（加速电压、光束电流、焊接速度、聚焦/离焦、光束振荡）、材料特性（合金类型、厚度、表面处理）和结果（渗透、孔隙度、微观结构、机械性能）。合并报告的统计措施，以量化参数的主导影响，并进行SWOT分析，以及研究差距分析。研究表明，真空电弧焊有效地克服了铜焊接的困难，同时产生的接头质量优于其他熔合工艺。EBW在铜缺陷最小的情况下实现了30毫米的深焊缝穿透，接头强度高达264兆帕，相当于基材强度的约95%。梁电流、焊接速度、焦点位置、振荡模式等关键焊接参数对焊接质量影响显著，其中梁电流对焊深影响最大。当将铜连接到不同的材料时，仔细的梁定位和振荡技术成功地控制了不必要的化合物形成，同时保持了连接强度。主要研究结果包括：焊缝质量控制中81%的变化是由光束电流引起的；偏移量为0.4 ~ 0.5 mm的策略梁定位优化了不同节点，实现了250 MPa的强度；振荡模式在控制金属间形成的同时降低了30%的孔隙度；在热管理系统的铜管连接应用方面仍存在重大的研究空白。该框架能够精确连接下一代能源和电子应用的高性能铜系统。

{"title":"Electron beam welding parameters for copper and dissimilar copper joints: Review, research gaps, and future challenges","authors":"Sathishkumar Duraisamy , Ana Horovistiz , Antonio Bastos , Bernardo Mascate , João M.S. Dias","doi":"10.1016/j.jajp.2025.100350","DOIUrl":"10.1016/j.jajp.2025.100350","url":null,"abstract":"<div><div>Copper welding presents significant challenges due to its high thermal conductivity and reflectivity, making traditional welding methods largely ineffective. Electron Beam Welding (EBW) offers a promising solution but requires precise parameter control to achieve optimal results. This study is a systematic review following a structured search of Scopus and Web of Science. After title–abstract–full text screening using predefined inclusion criteria (experimental EBW of copper or copper–dissimilar joints reporting process parameters and weld performance), 163 peer-reviewed articles were retained. For each study, the authors extracted process parameters (accelerating voltage, beam current, welding speed, focus/defocus, beam oscillation), material characteristics (alloy type, thickness, surface preparation), and outcomes (penetration, porosity, microstructure, mechanical properties). Reported statistical measures were consolidated to quantify the dominant influences of the parameters, and a SWOT analysis, along with a research gap analysis, was performed. Research indicates that vacuum-based EBW effectively overcomes copper welding difficulties while producing superior joint quality compared to other fusion processes. EBW achieves deep weld penetrations of up to 30 mm with minimal defects in copper, producing joint strengths of up to 264 MPa, equivalent to approximately 95% of the base material strength. Key welding parameters, including beam current, welding speed, focus position, and oscillation patterns, significantly influence weld quality, with beam current exerting the strongest effect on penetration depth. When joining copper to different materials, careful beam positioning and oscillation techniques successfully control unwanted compound formation while maintaining joint strength. Key findings establish that beam current accounts for 81% of the variance in weld quality control; strategic beam positioning with 0.4–0.5 mm offsets optimizes dissimilar joints, achieving strengths of 250 MPa; oscillation patterns reduce porosity by 30% while controlling intermetallic formation; and significant research gaps remain in copper tube joining applications for thermal management systems. This framework enables precision joining of high-performance copper systems for next-generation energy and electronics applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100350"},"PeriodicalIF":4.0,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145108666","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

Visualization of material flow in one-step double-acting FSW of AA1100: role of tracer type and morphology AA1100一步双作用FSW物料流可视化：示踪剂类型和形态的作用

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-09-16 DOI: 10.1016/j.jajp.2025.100349

Eko Prasetya Budiana, Anas Fikri Makarim, Heru Sukanto, Nurul Muhayat, Triyono

Aluminum is widely used in industry due to its lightweight, high strength, and cost-effectiveness. However, conventional fusion welding of aluminum often results in porosity defects. One-step Double-Acting Friction Stir Welding (ODFSW) is an advancement of the FSW technique that enables simultaneous double-sided welding in a single pass at sub-melting temperatures, thereby overcoming porosity issues in fusion welding while also addressing challenges in single-sided FSW of thicker plates, such as incomplete penetration and root flaws. The quality of ODFSW joints is strongly influenced by the material flow behavior during welding. To investigate this flow, the Tracer Insert Technique was employed. This study examines the effect of tracer material type and form on the visibility of material flow in ODFSW of AA1100 aluminum with a 1 mm pin overlap. Three types of tracers were used: SiO₂ powder, AA6061 powder, and ER5356 wire. Results revealed that powder-form tracers, particularly AA6061, provided better visualization due to more uniform distribution and higher color contrast caused by the presence of Mg₂Si precipitates. Multi-Attribute Decision Making (MADM) evaluation identified AA6061 as the most effective tracer, exhibiting minimal defects. Material flow visualization indicated distinct patterns, including flow from the advancing side (AS) to the retreating side (RS), material accumulation at the weld exit, onion ring formation, microvoids at pin tips, and homogeneous mixing in the mid-plate region. Additionally, a funnel-shaped flow profile and material concentration at the mid-thickness zone were observed, attributed to the mechanical interaction between the upper and lower tools.

铝因其重量轻、强度高、性价比高而广泛应用于工业领域。然而，传统的铝熔焊往往会产生气孔缺陷。一步双作用搅拌摩擦焊（ODFSW）是搅拌摩擦焊技术的一项进步，它可以在亚熔化温度下单道同时进行双面焊接，从而克服了熔焊中的气孔问题，同时也解决了较厚板的单面搅拌摩擦焊的挑战，如未焊透和根部缺陷。焊接过程中材料的流动行为对ODFSW接头的质量有很大影响。为了研究这种流动，采用了示踪剂插入技术。本研究考察了示踪材料类型和形式对引脚重叠1mm的AA1100铝ODFSW中物质流动可见性的影响。采用三种示踪剂：SiO₂粉、AA6061粉、ER5356丝。结果表明，粉末型示踪剂，特别是AA6061，由于Mg₂Si析出物的存在，其分布更均匀，颜色对比度更高，提供了更好的可视化效果。多属性决策（MADM）评价表明AA6061是最有效的示踪剂，缺陷最小。材料流动的可视化显示了明显的流动模式，包括从前进侧（AS）流向后退侧（RS）、焊缝出口的材料堆积、洋葱环的形成、针尖处的微空洞以及中板区域的均匀混合。此外，由于上下工具之间的机械相互作用，在中厚区观察到漏斗状的流动剖面和物质浓度。

{"title":"Visualization of material flow in one-step double-acting FSW of AA1100: role of tracer type and morphology","authors":"Eko Prasetya Budiana, Anas Fikri Makarim, Heru Sukanto, Nurul Muhayat, Triyono","doi":"10.1016/j.jajp.2025.100349","DOIUrl":"10.1016/j.jajp.2025.100349","url":null,"abstract":"<div><div>Aluminum is widely used in industry due to its lightweight, high strength, and cost-effectiveness. However, conventional fusion welding of aluminum often results in porosity defects. One-step Double-Acting Friction Stir Welding (ODFSW) is an advancement of the FSW technique that enables simultaneous double-sided welding in a single pass at sub-melting temperatures, thereby overcoming porosity issues in fusion welding while also addressing challenges in single-sided FSW of thicker plates, such as incomplete penetration and root flaws. The quality of ODFSW joints is strongly influenced by the material flow behavior during welding. To investigate this flow, the Tracer Insert Technique was employed. This study examines the effect of tracer material type and form on the visibility of material flow in ODFSW of AA1100 aluminum with a 1 mm pin overlap. Three types of tracers were used: SiO₂ powder, AA6061 powder, and ER5356 wire. Results revealed that powder-form tracers, particularly AA6061, provided better visualization due to more uniform distribution and higher color contrast caused by the presence of Mg₂Si precipitates. Multi-Attribute Decision Making (MADM) evaluation identified AA6061 as the most effective tracer, exhibiting minimal defects. Material flow visualization indicated distinct patterns, including flow from the advancing side (AS) to the retreating side (RS), material accumulation at the weld exit, onion ring formation, microvoids at pin tips, and homogeneous mixing in the mid-plate region. Additionally, a funnel-shaped flow profile and material concentration at the mid-thickness zone were observed, attributed to the mechanical interaction between the upper and lower tools.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100349"},"PeriodicalIF":4.0,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145095122","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 process gas mixtures on weld material characteristics and bead geometry for wire-arc directed energy deposition 工艺气体混合物对电弧定向能沉积焊接材料特性和焊头几何形状的影响

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-09-04 DOI: 10.1016/j.jajp.2025.100347

Michael Unger , Sebastian Zehetner , Thomas Klein , Aurel Arnoldt , Martin Schnall

Shielding gases are used in welding technologies to prevent contamination and protect the metallic melt from disadvantageous effects that air could cause on the weld. While argon is mostly used for gas metal arc welding of aluminum, this paper investigates the use of mixtures with traces of different gases. Various properties of the weld seams are assessed: Effects on bead geometry, microstructure, defects, and mechanical characteristics of the resulting material. Investigations were performed for single welds as well as directed energy deposited wire-arc specimens. For this purpose, single bead on plate with CO₂, N₂, and O₂ in the mixture and wall geometry samples with N₂ and O₂ were manufactured and subsequently analyzed. Nitrogen in the gas mixture is reducing the bead and deposit width and decreasing the grain size compared to the reference sample. This grain size reduction is due to the formation of nitrides in the weld material acting as nucleants for new grains. Nitrides were identified by energy dispersive X-ray spectroscopy. Furthermore, nitrogen is reducing the number of pores but not significantly their volume fraction. A similar effect is reported for used amounts of O₂ on smaller scale. The characteristic mechanical strength values are comparable to reported data, but the elongation is reduced when nitrogen is present in the shielding gas mixture.

保护气体在焊接技术中用于防止污染和保护金属熔体免受空气可能对焊缝造成的不利影响。虽然氩气主要用于铝的气体金属电弧焊，但本文研究了混合微量不同气体的使用。评估焊缝的各种特性：对焊缝几何形状、微观结构、缺陷和最终材料的机械特性的影响。对单焊缝和定向能沉积线弧试样进行了研究。为此，制作了含有CO2、N2和O2混合物的板上单球，以及含有N2和O2的壁几何样品，并随后进行了分析。与参考样品相比，混合气体中的氮气减少了珠层和沉积物的宽度，减小了晶粒尺寸。这种晶粒尺寸的减小是由于焊缝材料中氮化物的形成作为新晶粒的成核剂。利用能量色散x射线光谱对氮化物进行了鉴定。此外，氮会减少孔隙的数量，但不会显著减少孔隙的体积分数。据报道，在较小范围内使用的氧气量也有类似的效果。特征机械强度值与报道的数据相当，但当氮气存在于保护气体混合物中时，伸长率会降低。

{"title":"Effect of process gas mixtures on weld material characteristics and bead geometry for wire-arc directed energy deposition","authors":"Michael Unger , Sebastian Zehetner , Thomas Klein , Aurel Arnoldt , Martin Schnall","doi":"10.1016/j.jajp.2025.100347","DOIUrl":"10.1016/j.jajp.2025.100347","url":null,"abstract":"<div><div>Shielding gases are used in welding technologies to prevent contamination and protect the metallic melt from disadvantageous effects that air could cause on the weld. While argon is mostly used for gas metal arc welding of aluminum, this paper investigates the use of mixtures with traces of different gases. Various properties of the weld seams are assessed: Effects on bead geometry, microstructure, defects, and mechanical characteristics of the resulting material. Investigations were performed for single welds as well as directed energy deposited wire-arc specimens. For this purpose, single bead on plate with CO<sub>2</sub>, N<sub>2</sub>, and O<sub>2</sub> in the mixture and wall geometry samples with N<sub>2</sub> and O<sub>2</sub> were manufactured and subsequently analyzed. Nitrogen in the gas mixture is reducing the bead and deposit width and decreasing the grain size compared to the reference sample. This grain size reduction is due to the formation of nitrides in the weld material acting as nucleants for new grains. Nitrides were identified by energy dispersive X-ray spectroscopy. Furthermore, nitrogen is reducing the number of pores but not significantly their volume fraction. A similar effect is reported for used amounts of O<sub>2</sub> on smaller scale. The characteristic mechanical strength values are comparable to reported data, but the elongation is reduced when nitrogen is present in the shielding gas mixture.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100347"},"PeriodicalIF":4.0,"publicationDate":"2025-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145044702","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 varying stiffness on the interfacial failure behavior of isotactic polypropylene and porous alumina studied via DPD simulation 通过DPD模拟研究了不同刚度对等规聚丙烯与多孔氧化铝界面破坏行为的影响

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-08-21 DOI: 10.1016/j.jajp.2025.100343

Yoshitake Suganuma, James A. Elliott

This work studies a polymer–metal oxide bonded interface consisting of isotactic polypropylene (iPP) and a porous surface, and examines the impact of the stiffness of the polymeric component on the tensile strength of the interface using the dissipative particle dynamics (DPD) method. Our calculations reveal that an increase in the stiffness of iPP component leads to an increased tensile strength on the porous alumina even in an interfacial failure. The tensile failure mode observed on the porous surface is caused by the slippage of iPP component along the pore walls. An iPP component with a higher Young’s modulus is more resistant to deformation during tensile tests, which makes it difficult for the interfacial stress to reach the critical strain for the slippage, and thus results in an increased tensile strength of the bonded interface.

本文研究了由等规聚丙烯（iPP）和多孔表面组成的聚合物-金属氧化物键合界面，并使用耗散粒子动力学（DPD）方法研究了聚合物组分的刚度对界面抗拉强度的影响。我们的计算表明，即使在界面破坏中，iPP组件刚度的增加也会导致多孔氧化铝的抗拉强度增加。在多孔表面观察到的拉伸破坏模式是由iPP组分沿孔壁滑动引起的。杨氏模量越高的iPP构件在拉伸试验中抗变形能力越强，使得界面应力难以达到导致滑移的临界应变，从而导致粘结界面抗拉强度的提高。

引用次数: 0