Journal of Advanced Joining Processes最新文献_第4页

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。

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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。

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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。

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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。

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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

Continuous drive friction welding of commercial pure aluminum to copper: Metallographic and mechanical characterization of various cross-sections 商业纯铝与铜的连续驱动摩擦焊接：各种截面的金相和力学特性

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-08-19 DOI: 10.1016/j.jajp.2025.100342

Lucia Sauter , Martin Werz , Stefan Weihe

An electrically and mechanically sound joint between aluminum and copper is essential in modern manufacturing, particularly in the field of e-mobility, where the demand for integrated, lightweight, and high-performance conductors continues to grow. However, because of the distinct metallurgical characteristics of these materials, their joining presents significant metallurgical and process-related challenges, including the formation of brittle intermetallic compounds (IMCs). Rotary friction welding (RFW) has emerged as a promising solid-state joining technique, enabling high-integrity dissimilar material bonds through the reduction of heat input and reducing IMC formation. This study investigates the metallurgical and mechanical properties of the aluminum-copper joints produced by RFW. A comprehensive microstructural analysis was conducted using scanning electron microscopy (SEM) on both fracture surfaces and cross-sectional samples. Energy-dispersive X-ray spectroscopy (EDX) was employed to examine the IMC phases at the weld interface, providing insights into their formation and distribution. To evaluate the mechanical performance of the joints, tensile tests were performed on specimens with varying diameters, allowing for an assessment of the weld integrity across different residual cross sections. This approach enabled the determination of whether a strong bond extends throughout the weld region. In addition, hardness measurements were conducted to further characterize the mechanical properties of the joint. The results provide a deeper understanding of the microstructural evolution and mechanical behavior of aluminum-copper RFW joints. The insights gained contribute to optimizing joint performance and the development of reliable bimetallic connections for industrial applications.

在现代制造业中，特别是在对集成、轻量化和高性能导体的需求不断增长的电动汽车领域，铝和铜之间的电气和机械连接是必不可少的。然而，由于这些材料独特的冶金特性，它们的连接带来了重大的冶金和工艺相关挑战，包括脆性金属间化合物（IMCs）的形成。旋转摩擦焊（RFW）已经成为一种很有前途的固态连接技术，通过减少热量输入和减少IMC的形成，实现了高完整性的异种材料连接。研究了RFW生产的铝铜接头的冶金性能和力学性能。采用扫描电镜（SEM）对断口表面和横截面试样进行了全面的显微结构分析。利用能量色散x射线光谱（EDX）检查焊缝界面处的IMC相，了解其形成和分布。为了评估接头的力学性能，对不同直径的试件进行了拉伸试验，从而可以评估不同残余截面的焊缝完整性。这种方法可以确定牢固的粘结是否延伸到整个焊接区域。此外，还进行了硬度测量，以进一步表征接头的力学性能。研究结果为进一步了解铝-铜RFW接头的微观组织演变和力学行为提供了依据。所获得的见解有助于优化接头性能，并为工业应用开发可靠的双金属连接。

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引用次数: 0

Mechanistic insight into cooling-rate-driven bubble evolution and interfacial bonding strength in directly bonded Ti–PET materials 直接结合Ti-PET材料中冷却速率驱动气泡演化和界面结合强度的机理研究

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-08-18 DOI: 10.1016/j.jajp.2025.100345

Katsuyoshi Kondoh , Nodoka Nishimura , Kazuki Shitara , Shota Kariya , Ke Chen , Abdillah Sani Bin Mohd Najib , Junko Umeda

This study elucidates the mechanistic relationship between cooling rate and interfacial bubble evolution in direct bonding of commercially pure titanium (Ti) to polyethylene terephthalate (PET). Joints were fabricated via a thermal press-bonding process under two distinct cooling regimes—rapid and slow cooling—and the dynamic behavior of residual gas bubbles was analyzed through in-situ optical observation. Slow cooling was found to markedly reduce both the size and population density of interfacial bubbles, attributed to enhanced gas re-dissolution and diffusion within the softened PET matrix at elevated temperatures. Quantitative image analysis revealed that the bubble area fraction decreased by >50 % under slow cooling conditions. Tensile shear testing showed that joints fabricated under slow cooling exhibited significantly higher bond strength—up to 1.5 times greater than those produced under rapid cooling—highlighting the deleterious role of residual bubbles as interfacial defects. Fractographic observations further indicated that slow cooling altered bubble morphology from network-like, dome-shaped structures to isolated, spherical forms, thereby increasing the effective bonded area and promoting interfacial adhesion. These findings provide critical insight into thermally driven interfacial phenomena in metal–polymer joining and underscore the importance of thermal management strategies for optimizing joint integrity.

本研究阐明了工业纯钛（Ti）与聚对苯二甲酸乙二醇酯（PET）直接键合过程中冷却速率与界面气泡演化的机理关系。在快速冷却和慢速冷却两种不同冷却方式下，采用热压-键合工艺制备了接头，并通过原位光学观察分析了残余气泡的动态行为。研究发现，缓慢冷却可以显著减小界面气泡的大小和密度，这是由于在高温下软化PET基体内气体的再溶解和扩散增强。定量图像分析表明，在缓慢冷却条件下，气泡面积分数降低了50%。拉伸剪切测试表明，缓慢冷却下制造的接头具有明显更高的结合强度-高达快速冷却下制造的接头的1.5倍-突出了残余气泡作为界面缺陷的有害作用。断口形貌进一步表明，缓慢冷却改变了气泡形态，使其从网状、圆顶状结构转变为孤立的球形结构，从而增加了有效结合面积，促进了界面粘附。这些发现为研究金属-聚合物连接中的热驱动界面现象提供了重要见解，并强调了热管理策略对优化接头完整性的重要性。

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引用次数: 0

Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating 利用分散在Cu涂层中的Al2O3和TiC纳米颗粒控制AA6005激光焊接中的凝固裂纹

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-08-16 DOI: 10.1016/j.jajp.2025.100344

M.H. Khan , S. Jabar , T.I. Khan , H.R. Kotadia , P. Franciosa

Laser beam welding is a critical joining method for wrought 6xxx series aluminium (Al) alloys; however, its broader adoption is hindered by the susceptibility to solidification cracking, which undermines weld integrity and restricts the production of high-quality joints. To mitigate cracking susceptibility, this study explores a novel approach involving the use of alumina (Al₂O₃) and titanium carbide (TiC) nanoparticles introduced into the fusion zone of laser welded AA6005 aluminium sheets via electrophoretic deposition (CuSO₄ bath, ∼40 nm nanoparticles, varying concentrations/times). Microstructural analysis revealed that the incorporation of both Al₂O₃ and TiC nanoparticles on AA6005 led to an overall 65% grain refinement, effectively preventing centreline cracking during welding. Lap shear testing demonstrated a significant improvement in joint strength, with a 10% increase for Al₂O₃ coated samples and a 13% increase for TiC coated welds compared to the uncoated material. Notably, TiC outperformed Al₂O₃ at higher concentrations, exhibiting more uniform dispersion with reduced agglomeration and porosity. In contrast, Al₂O₃ showed a tendency toward particle clustering and pore formation at elevated concentrations, which limited its strengthening efficiency. This highlights the potential of nanoparticle reinforcement for enhancing the reliability and performance of laser welded 6xxx aluminium alloys.

激光束焊接是变形6xxx系列铝（Al）合金的一种关键连接方法；然而，它的广泛采用受到易于凝固开裂的阻碍，这破坏了焊缝的完整性，限制了高质量接头的生产。为了减轻开裂敏感性，本研究探索了一种新的方法，包括使用氧化铝（Al2O3）和碳化钛（TiC）纳米颗粒通过电泳沉积（CuSO4镀液，~ 40 nm纳米颗粒，不同浓度/时间）引入激光焊接AA6005铝板的熔合区。显微组织分析表明，Al2O3和TiC纳米颗粒在AA6005上的掺入使晶粒细化了65%，有效地防止了焊接过程中的中线开裂。搭接剪切测试表明，与未涂覆材料相比，涂覆Al2O3样品的接头强度提高了10%，涂覆TiC的焊缝强度提高了13%。值得注意的是，在较高浓度下，TiC优于Al2O3，表现出更均匀的分散，减少了团聚和孔隙度。相反，Al2O3在高浓度下表现出颗粒聚集和孔隙形成的趋势，限制了其强化效果。这突出了纳米颗粒增强在提高激光焊接6xxx铝合金可靠性和性能方面的潜力。

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引用次数: 0

LSDF-Net: An efficient lightweight defect detection method for ultrasonic welding surfaces LSDF-Net：一种高效轻量级的超声焊接表面缺陷检测方法

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-08-16 DOI: 10.1016/j.jajp.2025.100339

Shuhang Zhang , Xin Jin , Zhijiang Lou , Sen Wang , Shan Lu , Yifan He

This paper proposes LSDF-Net, a lightweight and high-speed detection network designed to address the challenges of insufficient accuracy and high computational cost in ultrasonic welding surface defect detection. Built upon the YOLOv8 architecture, LSDF-Net integrates a Dynamic Surface Detail Fusion Module (DSDFM) to enhance multi-scale feature representation and introduces a Lightweight Shared Convolution and Separate Batch Normalization detection head (LSCSBD) to reduce parameters and accelerate inference. In addition, a LAMP-based pruning strategy is applied, which achieves a 67% reduction in model size and a 48% reduction in computational cost with almost no performance degradation. Experimental results on both a self-constructed ultrasonic welding defect dataset and the public NEU-DET dataset demonstrate that LSDF-Net achieves the best overall performance, striking an excellent balance between accuracy and real-time inference. These results highlight its strong potential for real-time industrial defect detection applications.

针对超声焊接表面缺陷检测精度不足、计算成本高的问题，提出了一种轻量、高速的检测网络LSDF-Net。基于YOLOv8架构，LSDF-Net集成了动态表面细节融合模块（DSDFM）来增强多尺度特征表示，并引入了轻量级共享卷积和单独批归一化检测头（LSCSBD）来减少参数和加速推理。此外，应用了基于lamp的剪枝策略，在几乎没有性能下降的情况下，模型尺寸减少了67%，计算成本减少了48%。在自构建的超声焊接缺陷数据集和公开的nue - det数据集上的实验结果表明，LSDF-Net在准确性和实时推理之间取得了很好的平衡，取得了最佳的综合性能。这些结果突出了它在实时工业缺陷检测应用中的强大潜力。

引用次数: 0

Surface cracks repair in AA6061-T6 aluminum alloys using friction stir processing 搅拌摩擦法修复AA6061-T6铝合金表面裂纹

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-08-11 DOI: 10.1016/j.jajp.2025.100340

Fadi Al-Badour , Ahmad H. Bawagnih , Ahmed Ali , Rami K. Suleiman , Necar Merah

Friction Stir Welding (FSW) is an advanced solid-state joining technique that offers an effective solution for repairing surface cracks in aluminum alloys. This study investigates the repair of an artificially induced 2 mm square groove in AA6061-T6 aluminum alloy plate; resemble pre-repair preparation, using friction stir processing (FSP), incorporating an aluminum filler rod and silicon carbide (SiC) nanoparticles as a reinforcement to ensure complete crack sealing. FSP was conducted on both cracked and crack-free samples, with a focus on the impact of tool offset during the repair process. Tool offsets of 0 mm, 1.75 mm, and 3.5 mm were employed toward the advancing side to assess their influence on the repair process. Mechanical testing, microstructural characterization, temperature, and force analysis were performed to comprehensively evaluate the repair strategy. The repaired samples exhibited an average ultimate tensile strength (UTS) of approximately 180 MPa, closely matching the 186 MPa observed in crack-free bead-on-plate welds. Additionally, the microhardness at stir zone (SZ) improved to average values of 77 HV for 0 mm offset and 80 HV for 1.75 mm offset, compared to 70 HV in the bead-on-plate welds . Despite the presence of microstructural defects, the use of tool offset contributed to satisfactory mechanical performance. However, samples welded with 0 mm tool offset exhibited slightly superior mechanical properties. Overall, this research highlights the feasibility of using FSP, combined with SiC nanoparticles reinforced filler material and tool offset control, as a promising approach for effective surface crack repair in aluminum alloys, providing a foundation for further process optimization and industrial application.

搅拌摩擦焊（FSW）是一种先进的固态连接技术，为修复铝合金表面裂纹提供了有效的解决方案。研究了AA6061-T6铝合金板人工诱导2 mm方槽的修复问题；类似于预修复准备，使用摩擦搅拌处理（FSP），结合铝填充棒和碳化硅纳米颗粒作为增强剂，以确保完全密封裂缝。FSP对裂纹和无裂纹样品进行了研究，重点研究了修复过程中刀具偏移的影响。刀具偏移量分别为0 mm、1.75 mm和3.5 mm，以评估其对修复过程的影响。力学测试、显微组织表征、温度和力分析进行了综合评估修复策略。修复样品的平均极限抗拉强度（UTS）约为180 MPa，与无裂纹板上焊的186 MPa非常接近。此外，搅拌区（SZ）的显微硬度在偏移量为0 mm时提高到77 HV，偏移量为1.75 mm时提高到80 HV，而焊珠对板焊接的显微硬度为70 HV。尽管存在显微组织缺陷，但刀具偏移的使用有助于获得令人满意的机械性能。然而，用0 mm刀具偏移焊接的样品表现出稍好的机械性能。综上所述，本研究突出了FSP与SiC纳米颗粒增强填充材料和刀具偏移控制相结合的可行性，为进一步的工艺优化和工业应用奠定了基础。

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引用次数: 0