Pub Date : 2025-11-28DOI: 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).
{"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}
Pub Date : 2025-11-10DOI: 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 t8/5 ≈ 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.
{"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}
Pub Date : 2025-11-08DOI: 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.
{"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}
Pub Date : 2025-11-08DOI: 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 (SiN 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.
{"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}
Pub Date : 2025-11-05DOI: 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.
{"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}
Pub Date : 2025-10-27DOI: 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.
{"title":"Mechanical properties of intermetallic compounds at solder joint interfaces investigated using nanoindentation technique","authors":"Wei-Rong Yang , Kiyokazu Yasuda , Jenn-Ming Song","doi":"10.1016/j.jajp.2025.100356","DOIUrl":"10.1016/j.jajp.2025.100356","url":null,"abstract":"<div><div>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.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100356"},"PeriodicalIF":4.0,"publicationDate":"2025-10-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145415252","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-10-10DOI: 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.
{"title":"Exploring the hybridization of wire-arc additive manufacturing and resistance spot welding","authors":"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","doi":"10.1016/j.jajp.2025.100354","DOIUrl":"10.1016/j.jajp.2025.100354","url":null,"abstract":"<div><div>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.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100354"},"PeriodicalIF":4.0,"publicationDate":"2025-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145324211","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-10-01DOI: 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.
{"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}
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.
{"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}
Pub Date : 2025-09-23DOI: 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.
{"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}
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