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

Crack-free manufacture of single weld tracks on aluminum alloy 6013 with the usage of laser beam shaping and oscillation strategies 利用激光束整形和振荡策略制造6013铝合金单焊道无裂纹

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100269

Thomas Stoll , Maximilian Schmitt , Laura-Marie Müller , Frank Palm

The present paper investigates the application of laser beam shaping and laser beam oscillations (wobbling) for laser processing of the crack-prone aluminum alloy 6013, used in automotive and aerospace applications. A comparison of different laser beam profiles, such as the commonly used Gaussian profile, a ring-core distribution with the intensity of 50 % in the ring and 50 % in the core, and a ring-shaped beam profile shows different cracking behavior of the material. The ring-shaped beam profile shows the most promising results due to a reduction of the thermal gradient G and an enhancement of the growth rate R, which isalso stated by the state of the art. A combination of laser beam shaping and laser beam oscillations shows reproducible crack-free processing of Al6013 sheets at all three beam profiles at different parameter combinations. The crack elimination can be attributed to the emergence of a more pronounced equiaxed grain structure in the fusion zone of the weld with the application of laser beam oscillations and laser beam shaping. Thus, the temperature gradient G, the growth rate R and, therefore, the cooling rate can be controlled with the presented variation of the laser beam shapes and scanning strategies. Furthermore, the penetration depth of the laser at a Gaussian beam profile can be reduced using laser beam shaping, showing shallower melt pools with a lower depth-to-width aspect ratio, also suitable for the process of powder bed fusion of metals using a laser-based system (PBF-LB/M).

本文研究了激光束整形和激光束振荡（摆动）在激光加工汽车和航空航天用易开裂铝合金6013中的应用。通过比较不同的激光束分布，如常用的高斯分布、环内强度为50%、芯内强度为50%的环形-芯分布和环形光束分布，可以看出材料的不同开裂行为。由于热梯度G的减小和生长速率R的提高，环形光束轮廓显示出最有希望的结果，这也是目前技术水平所陈述的。激光束整形和激光束振荡相结合的结果表明，在不同的参数组合下，三种激光束轮廓均可再现Al6013板材的无裂纹加工。采用激光束振荡和激光束整形后，焊缝熔合区出现了更明显的等轴晶粒结构，从而消除了裂纹。因此，温度梯度G、生长速率R以及冷却速率都可以通过改变激光束形状和扫描策略来控制。此外，使用激光束整形可以降低激光在高斯光束剖面上的穿透深度，显示出较浅的熔池和较低的深宽长宽比，也适合使用基于激光的系统（PBF-LB/M）进行粉末床熔合金属的过程。

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引用次数: 0

Special issue: 3rd international conference on advanced joining processes 2023 (AJP 2023)

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100248

Lucas F.M. da Silva , Paulo Martins , Uwe Reisgen

引用次数: 0

Laser welding thermal analysis of 20mm-thick EH40 steel with gap through an equivalent thermal conductivity method 通过等效导热法对有间隙的 20mm 厚 EH40 钢进行激光焊接热分析

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100266

Guolong Zhang , Yu Huang , Xuanrui Liu , Hui Wang , Youmin Rong , Yifan Peng , Jiajun Xu

Laser welding of thick plates is extremely sensitive to the gap between joints. With the same laser welding parameters, slight adjustment of the gap can lead to different weld morphologies. An appropriate joint gap is conducive to increasing the penetration depth and reducing defects. To investigate the influence of the gap between butt joints on the penetration depth during single-pass laser welding of 20 mm thick EH40 steel, five groups of experiments were conducted with a laser power of 15 kW and a welding speed of 10mm/s, and gap sizes ranging from 0 to 0 .4mm. A finite element model of the temperature field was established for the experimental samples. Using the concept of equivalent substitution, the heat transfer process was used to replace the downward flow of the molten pool along the gap, and the equivalent thermal conductivity was derived to predict the penetration depth under different gap sizes. The results showed that within the gap range of 0–0.3 mm, the penetration depth increased and spatter decreased as the gap increased. When the gap exceeded 0.2 mm, weld depression began to appear. The maximum penetration depth of 19.33 mm was achieved when the gap was 0 .3mm. When the gap reached 0.4 mm, unacceptable severe collapse occurred in the weld. Additionally, the accuracy of the temperature field simulation results was verified by the experimental results.

激光焊接厚板对焊点之间的间隙极为敏感。在相同的激光焊接参数下，间隙的细微调整会导致不同的焊接形态。适当的焊点间隙有利于增加熔深和减少缺陷。为了研究单程激光焊接 20 毫米厚 EH40 钢时对接接头间隙对熔透深度的影响，在激光功率为 15 千瓦、焊接速度为 10 毫米/秒、间隙大小为 0 至 0.4 毫米的条件下进行了五组实验。为实验样品建立了温度场有限元模型。利用等效替代的概念，用传热过程替代熔池沿间隙向下流动的过程，得出等效导热系数，从而预测不同间隙尺寸下的熔透深度。结果表明，在 0-0.3 毫米的间隙范围内，随着间隙的增大，穿透深度增加，飞溅减少。当间隙超过 0.2 毫米时，开始出现焊接凹陷。当间隙为 0.3 毫米时，最大熔深为 19.33 毫米。当间隙达到 0.4 毫米时，焊缝出现了无法接受的严重塌陷。此外，实验结果也验证了温度场模拟结果的准确性。

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引用次数: 0

Exploring wire-arc additive manufactured rivets for joining hybrid electrical busbars

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100272

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 presents a joining by plastic deformation process for fabricating hybrid electrical busbars made from copper and aluminum sheets. The process comprises the innovative use of wire-arc additive manufacturing to deposit copper rivets at specific locations on the copper sheets, the machining of slots with the required geometry in the aluminum sheets, and the compression of the copper sheets to force the rivets into the pre-machined slots of the aluminum sheets, creating form-closed mechanical interlocks. The work combines experimentation and finite element modeling to analyze the influence of the most significant process parameters, and the electrical performance of the hybrid busbar joints is evaluated and compared to that of conventional fastened joints at different service temperatures. Results demonstrate the effectiveness and potential advantages of the new joining by plastic deformation process for fabricating hybrid electrical busbars.

引用次数: 0

Characterization of physical metallurgy of quenching and partitioning steel in pulsed resistance spot welding: A simulation-aided study 脉冲电阻点焊中淬火和分区钢的物理冶金特性：模拟辅助研究

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100264

Ali Bahmani, Vahid Feizollahi, Rouholah Ashiri

This study mainly focuses on the microstructure evolution of QP980 steel during resistance spot welding and its influence on the mechanical performance of resistance spot welds which is a critical influencing factor on the quality of body-in-white at the service condition. It is observed that the thermomechanically engineered microstructure of QP980 steel changes to form metastable phases such as martensite in the fusion zone and the heat affected zone due to rapid cooling induced by the thermal cycle of the welding. A finite element modeling of the welding process was used to predict the weldment heat distribution, thermal history and microstructure evolution in different welding zones. The modeled thermal history of the weldments shows that the peak temperature in the four-pulse resistance spot welding is delayed because of pulsed welding conditions and holding times between the welding pulses. This heat management approach in pulsed welding prevents void formation. The modeled thermal history and rapid heating, and cooling conditions are discussed here to predict the microstructure evolution and transformation in the fusion and reheated zones. The modeled results were helpful in the prediction of the microstructure at different weld zones. Then the strategic links between the microstructure and mechanical performance of the welded alloy are discussed thoroughly. The microhardness profile of the weld is discussed from a microstructural point of view to disclose the physical metallurgy of the welds. Softening phenomena were not observed in the sub-critical heat affected zone.

本研究主要关注 QP980 钢在电阻点焊过程中的微观结构演变及其对电阻点焊机械性能的影响，而机械性能是白车身在使用状态下质量的关键影响因素。研究发现，由于焊接热循环引起的快速冷却，QP980 钢的热机械工程微观结构发生了变化，在熔合区和热影响区形成了马氏体等易变相。焊接过程的有限元模型用于预测不同焊接区的焊接热分布、热历史和微观结构演变。焊接件的热历史模型显示，由于脉冲焊接条件和焊接脉冲之间的保持时间，四脉冲电阻点焊的峰值温度被延迟。脉冲焊接中的这种热量管理方法可防止空洞的形成。本文讨论了模型热历史、快速加热和冷却条件，以预测熔合区和再加热区的微观结构演变和转变。模型结果有助于预测不同焊接区的微观结构。然后深入讨论了焊接合金的微观结构与机械性能之间的战略联系。从微观结构的角度讨论了焊缝的显微硬度曲线，以揭示焊缝的物理冶金学。在亚临界热影响区未观察到软化现象。

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引用次数: 0

Corrigendum to “Enhancing bending strength in continuous drive friction welding of PEEK polymer cylinders through the innovative progressively increased welding area method” [Journal of Advanced Joining Processes 10 (2024) 100255]

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100258

Chil-Chyuan Kuo, Hua-Xhin Liang, Song-Hua Huang, Armaan Farooqui, Shih-Feng Tseng

The authors regret missing to add the contract number NSTC 113–2221-E-131-023 to the funding statement.

引用次数: 0

A comprehensive techno-economic and environmental comparison of plasma-treated adhesive-bonded thermoplastic composites 等离子体处理的粘合剂粘结热塑性复合材料的技术经济和环境综合比较

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100268

Chiara Mandolfino, Lucia Cassettari, Marco Pizzorni, Luigi Benvenuto, Enrico Lertora

Thermoplastic composites are gaining attention for their ability to support a circular economy, shifting away from traditional cost-driven design. Unlike thermoset composites, commonly used in automotive and aerospace sectors, thermoplastic composites offer recyclability, promoting environmental and economic sustainability. Adhesive bonding in thermoplastic composites provides even stress distribution, maintaining structural integrity and reducing delamination risks, which is crucial for lightweight design in transport and renewable energy applications. Optimising adhesive bonded joints is essential to improve structural integrity, efficiency and sustainability. This involves balancing technical, economic and environmental factors, with surface preparation, plasma treatment in particular, playing a key role.

This paper provides a comprehensive techno-economic-environmental comparison of adhesive bonded joints. The study integrates cost-effectiveness, production efficiency and environmental impact assessments to guide informed decision-making. The methodology includes preparing substrates with low-pressure plasma surface treatments, forming adhesive-bonded joints with different adhesives, and optimising process parameters using Response Surface Methodology (RSM). A Life Cycle Assessment (LCA) on optimised scenarios enhances Tensile Shear Strength (TSS). The study concludes with a comprehensive comparison, offering insights for resilient, efficient and sustainable engineering solutions.

热塑性复合材料能够支持循环经济，摆脱传统的成本驱动型设计，因而备受关注。与汽车和航空航天领域常用的热固性复合材料不同，热塑性复合材料具有可回收性，促进了环境和经济的可持续发展。热塑性复合材料中的粘合剂粘接可提供均匀的应力分布，保持结构完整性并降低分层风险，这对于运输和可再生能源应用领域的轻量化设计至关重要。优化粘合接头对于提高结构完整性、效率和可持续性至关重要。这涉及到技术、经济和环境因素之间的平衡，其中表面处理，尤其是等离子处理起着关键作用。该研究综合了成本效益、生产效率和环境影响评估，为明智决策提供指导。研究方法包括用低压等离子表面处理技术制备基材，用不同的粘合剂形成粘合接头，以及使用响应面方法（RSM）优化工艺参数。对优化方案进行生命周期评估（LCA），以提高拉伸剪切强度（TSS）。研究最后进行了综合比较，为弹性、高效和可持续的工程解决方案提供了启示。

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引用次数: 0

Improving the joint strength of thermoplastic composites joined by press joining using laser-based surface treatment 利用激光表面处理技术提高热塑性复合材料的接合强度

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100260

Alexander Liebsch , Daniel Wohlfahrt , Thomas Kuntze , Levin Schilling , Jana Gebauer , Robert Kupfer , Niels Modler , Andrés Fabián Lasagni , Maik Gude

Fibre-reinforced thermoplastic composites (TPC) provide an automated and cost-effective solution for their use in lightweight structures in series production. The combination of different material configurations allows the design of highly stress tolerant components. Previous studies demonstrated that the combination of TPC sheets, TPC hollow profiles and injection moulding compounds is even suitable for crash-relevant automotive parts. All three components are combined during the injection moulding process. To prevent collapse, the part must remain in a consolidated state and cannot be preheated. However, this results in poor adhesion between the hollow profile, the bulk material, and the TPC sheet. Previous studies have shown that the bonding strength between the hollow profile and the injection moulding compound can be increased by surface pre-treatment using laser structuring and plasma technology. In this work, laser structuring is employed to enhance the bonding strength between the hollow profile and the TPC sheet. Microscopy analysis is used to investigate the resulting surface morphology. Subsequently, single-lap-shear (SLS) specimens are produced by pressing the TPC sheets onto the flat part. The resulting bonding strengths are then evaluated by tensile shear tests. The study analyses the impact of various pre-treatment parameters on the bonding strength. Furthermore, it investigates the effect of sheet temperature on the bonding strength, including specimens without pre-treatment. Finally, the results of the surface treatment of hollow composite profiles are discussed.

纤维增强热塑性复合材料（TPC）为轻质结构的批量生产提供了自动化和经济高效的解决方案。将不同的材料配置组合在一起，可以设计出具有高度应力承受能力的部件。先前的研究表明，TPC 板材、TPC 中空型材和注塑化合物的组合甚至适用于与碰撞有关的汽车部件。在注塑成型过程中，这三种成分会结合在一起。为防止塌陷，部件必须保持固结状态，且不能预热。然而，这会导致中空型材、散装材料和 TPC 片材之间的粘合力较差。以往的研究表明，通过使用激光成型和等离子技术进行表面预处理，可以提高中空型材与注塑模具之间的粘合强度。在这项工作中，采用了激光成型技术来提高中空型材与 TPC 板材之间的粘合强度。显微镜分析用于研究由此产生的表面形态。随后，通过将 TPC 片材压到平面部件上，制作出单层剪切（SLS）试样。然后通过拉伸剪切试验评估粘接强度。研究分析了各种预处理参数对粘接强度的影响。此外，还研究了板材温度对粘接强度的影响，包括未进行预处理的试样。最后，还讨论了空心复合材料型材表面处理的结果。

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引用次数: 0

Ablation treatment of CFRP via nanosecond pulsed Ytterbium-doped fiber laser: Effects of process parameters on surface morphology and shear strength of adhesive bonded joints 纳秒脉冲掺镱光纤激光烧蚀CFRP：工艺参数对粘结接头表面形貌和抗剪强度的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-11-01 DOI: 10.1016/j.jajp.2024.100270

Chiara Mandolfino , Fabrizio Moroni , Marco Pizzorni

Adhesive bonding is the joining technique that provides the maximum exploitation of Carbon Fiber Reinforced Polymers (CFRPs) for structural applications. However, it is necessary to attain a high-strength adhesive bond, achieved by removing surface contaminants, such as mold release agents, and simultaneously generating a surface structure suitable to increase the actual contact surface area. The purpose of the research work presented in this paper is to evaluate the effect of process parameters of a nanosecond pulsed laser pre-bonding surface treatment on the ablation of thermoset matrix CFRP substrates. In particular, the link between the volume of ablated material and the tensile shear strength (TSS) of adhesive bonded joints was evaluated by lap-shear tests, profilometer surveys, and Scanning Electron Microscope (SEM) analysis. ANOVA and regression models were used to highlight the influence of laser parameters, with power emerging as the most significant factor, and energy density proving pivotal for joint strength. Line spacing was also significant, while scanning direction had negligible impact. The key outcomes of the study demonstrated that controlled laser ablation plays a critical role in determining joint performance. A negative correlation was found between TSS and the thickness of ablated material, indicating that excessive ablation weakens the bond. Optimal joint strength was achieved with moderate fiber exposure while maintaining matrix integrity, emphasizing the need for precise control over laser parameters. Fracture surface analyses revealed distinct failure mechanisms, ranging from cohesive failure within the adhesive layer to interfacial failure at the fiber-matrix boundary, depending on the ablation conditions. The findings provide clear guidelines for optimizing laser surface treatments to enhance the structural performance of CFRP adhesive joints in practical applications.

粘接是一种最大限度地利用碳纤维增强聚合物（CFRPs）用于结构应用的连接技术。然而，有必要通过去除表面污染物（如脱模剂），同时产生适合增加实际接触表面积的表面结构，来获得高强度的粘合。本文的研究目的是评价纳秒脉冲激光预键合表面处理工艺参数对热固性CFRP基板烧蚀的影响。特别是，烧蚀材料的体积与胶结接头的抗拉剪切强度（TSS）之间的联系通过搭接剪切试验、轮廓仪测量和扫描电子显微镜（SEM）分析进行了评估。利用方差分析和回归模型来突出激光参数的影响，功率是最重要的因素，能量密度是影响关节强度的关键因素。行间距也很重要，而扫描方向的影响可以忽略不计。该研究的主要结果表明，受控激光烧蚀在确定关节性能方面起着关键作用。TSS与烧蚀材料的厚度呈负相关，表明过度烧蚀削弱了键合。在保持基体完整性的同时，通过适度的纤维暴露实现了最佳的接头强度，强调了对激光参数精确控制的必要性。断裂面分析揭示了不同的破坏机制，从粘结层内的内聚破坏到纤维-基体边界的界面破坏，这取决于烧蚀条件。研究结果为在实际应用中优化激光表面处理以提高CFRP粘接接头的结构性能提供了明确的指导。

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引用次数: 0

Investigation of the electrical quality and long-term stability of aluminum ground stud connections in automotive applications 汽车应用中铝接地螺栓连接的电气质量和长期稳定性调查

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2024-10-16 DOI: 10.1016/j.jajp.2024.100262

Viktor Haak, Keke Yang, Gerson Meschut

The rapid advancement in the electrification of modern vehicles has led to a continuous increase in electrical consumers for various comfort and safety functions. Ground studs serve as the electrical interface between the conductive vehicle body and the onboard network. Drawn arc stud welding is an economical and established joining process for producing ground stud joints. The circuits in the onboard network are increasingly subject to greater demands regarding current-carrying capacity and long-term stability. Reliable signal and power transmission require minimal contact resistance at the electrical connection points of the ground stud system and must withstand various operating and environmental conditions over the entire service life. In this study, a ground stud made of AlMg5, with a ZnNi-coated steel cap nut was used on a 2.0 mm thick sheet of AlMg3. The electrical connection of the ground studs was made using tinned copper cable lugs and 35 mm² cables. To analyze the electrical resistance behavior in an accelerated test, the ground studs were subjected to a superimposed load with a cyclic current profile for 1008 h under changing climatic conditions. The results show that under the chosen operational and environmental conditions, accelerated aging and intermittent resistance behavior occur. A characteristic drop in resistance during the test indicates the failure point of the electrical connection. The cause of failure can be attributed to media penetration into the electrical contact zone. A failure of the electrical connection was observed after 512 h.

随着现代汽车电气化的快速发展，用于各种舒适和安全功能的用电量不断增加。接地螺栓是导电车身与车载网络之间的电气接口。拉弧螺柱焊接是生产接地螺柱接头的一种经济、成熟的连接工艺。车载网络中的电路对载流能力和长期稳定性的要求越来越高。可靠的信号和电力传输要求接地螺柱系统电气连接点的接触电阻最小，并且必须在整个使用寿命期间经受住各种操作和环境条件的考验。在这项研究中，在 2.0 毫米厚的 AlMg3 板上使用了由 AlMg5 制成的接地螺柱，该螺柱带有一个 ZnNi 涂层钢帽螺母。接地螺栓的电气连接使用镀锡铜电缆耳和 35 mm² 电缆。为了分析加速试验中的电阻行为，接地螺栓在不断变化的气候条件下承受了 1008 小时的周期电流曲线叠加负载。结果表明，在选定的操作和环境条件下，会出现加速老化和间歇性电阻行为。测试期间电阻下降的特征表明了电气连接的故障点。故障原因可能是介质渗入电气接触区。512 小时后观察到电气连接失效。

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引用次数: 0