Journal of Advanced Joining Processes最新文献_第5页

Comparison of the economic efficiency and sustainability of two debonding processes for structurally bonded sills 两种结构粘接工艺的经济效率和可持续性比较

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-07-25 DOI: 10.1016/j.jajp.2025.100332

Alex Jordan , Lucas Hermelingmeier , Julian Gilich , Gerson Meschut , Marco De Santis , Alexander Schlüter

In light of growing demands for resource efficiency and sustainability in vehicle engineering, the environmentally compatible separation of structural adhesive joints is gaining increasing relevance. This study presents a comparative analysis of two physically based debonding methods: the established hot-air process and a cryogenic cold process based on liquid nitrogen (LN₂). The primary objective is to assess the ecological impact and process-related sustainability of both approaches.

Experimental investigations were conducted on a component-representative triple-sheet structure that simulates common automotive flange joints. Thermal input was applied either by convective heating using a hot air gun or by direct cooling through a contact-based LN₂ tool. The resulting temperature profiles were recorded using spatially distributed thermocouples. Subsequently, the outer panel was selectively debonded to replicate a repair scenario, and the mechanical integrity of the remaining adhesive joint was evaluated through Mode I testing of l-shaped specimens. Process data served as input for an Life Cycle Assessment (LCA) according to DIN EN ISO 14,040.

The cryogenic method achieved a 40 % reduction in carbon footprint compared to the hot-air process (0.337 kg vs. 0.559 kg CO₂-equivalents), primarily due to its shorter process time and more efficient heat transfer. While the hot-air method’s impact is mainly driven by electrical energy use, that of the cold method stems from cryogenic media consumption. Notwithstanding certain disadvantages in specific impact categories, the LN₂-based process exhibits a superior overall ecological performance and signifies a promising solution for repair- and recycling-oriented adhesive separation in structural vehicle applications.

随着汽车工程对资源效率和可持续性的要求越来越高，结构粘接接头的环境兼容分离越来越重要。本研究对比分析了两种基于物理的脱粘方法：已建立的热空气法和基于液氮（LN2）的低温冷法。主要目标是评估这两种方法的生态影响和与过程有关的可持续性。以具有代表性的三板结构为研究对象，模拟了常见的汽车法兰连接。热输入可以通过热风枪对流加热，也可以通过接触式LN2工具直接冷却。利用空间分布的热电偶记录得到的温度分布。随后，有选择地剥离外面板以复制修复场景，并通过l形试件的I型测试评估剩余粘合接头的机械完整性。根据DIN EN ISO 14040，过程数据作为生命周期评估（LCA）的输入。与热空气法相比，深冷法的碳足迹减少了40% （0.337 kg对0.559 kg二氧化碳当量），这主要是由于其更短的工艺时间和更有效的传热。热空气法的影响主要是由电能的使用驱动的，而冷法的影响则源于低温介质的消耗。尽管在特定的影响类别中存在一定的缺点，但基于ln2的工艺表现出优越的整体生态性能，并标志着结构车辆应用中以修复和回收为导向的粘合剂分离的有希望的解决方案。

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引用次数: 0

The effect of heat input on the residual stress distribution in gas-metal arc welding of carbon steel: Simulation and experimental methods 热输入对碳钢气-金属电弧焊残余应力分布的影响：模拟与实验方法

IF 4 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-07-25 DOI: 10.1016/j.jajp.2025.100333

Amir Dadkhah , Mahmoud Sarkari Khorrami , Seyed Farshid Kashani-Bozorg , Reza Miresmaeili

A major challenge in fusion welding is the development of residual stresses and distortions, stemming primarily from non-uniform thermal cycles during welding. These stresses adversely influence fatigue life, corrosion resistance, and dimensional stability of engineering components. Heat input is a crucial parameter governing residual stress formation. Conventional experimental methods for residual stress determination are often time-consuming or destructive, making simulation an efficient alternative for stress prediction. This study assessed the effect of heat input on residual stress in the gas metal arc welding (GMAW) process through integrated simulation and hole-drilling measurements. For this purpose, A516 Gr70 steel plates were welded using the GMAW technique with varying heat inputs, both with and without a back welding. After characterizing microstructure and mechanical properties, residual stresses were quantified via the hole-drilling method. Numerical simulation employed Abaqus with the Goldak double-ellipsoid heat source model and element birth-and-death technique, with results validated against experimental data. The microhardness value of the weld zone produced by the lowest heat input was found to be ∼198 HV, with a microstructure dominated by pearlite and varying morphologies of ferrites. Simulation revealed peak residual stresses in the heat-affected zone (HAZ) and weld center across all heat inputs. The reduction in heat input and applying the back welding resulted in less tensile residual stresses in most areas and slightly increased compressive residual stresses in areas farther from the HAZ. Four-channel thermocouple measurements and numerical simulation provided detailed thermal analysis during welding, with simulated residual stresses showing 96 % agreement with hole-drilling results, validating both methodologies.

熔焊的一个主要挑战是残余应力和变形的发展，主要源于焊接过程中不均匀的热循环。这些应力对工程部件的疲劳寿命、耐腐蚀性和尺寸稳定性产生不利影响。热输入是控制残余应力形成的关键参数。传统的残余应力测定实验方法往往耗时或破坏性，使模拟成为应力预测的有效替代方法。本研究通过综合模拟和钻孔测量，评估了热输入对气体保护焊（GMAW）过程中残余应力的影响。为此，A516 Gr70钢板采用不同热量输入的GMAW技术焊接，有或没有背焊。在表征微观组织和力学性能后，通过钻孔法对残余应力进行量化。数值模拟采用Abaqus软件，采用Goldak双椭球热源模型和单元生死技术，并与实验数据进行了验证。最低热输入产生的焊缝区显微硬度值为~ 198 HV，显微组织以珠光体和不同形态的铁素体为主。模拟结果表明，热影响区（HAZ）和焊缝中心的残余应力峰值贯穿所有热输入。减少热输入和应用背焊导致大多数区域的拉伸残余应力较小，而远离热影响区区域的压残余应力略有增加。四通道热电偶测量和数值模拟提供了焊接过程中详细的热分析，模拟的残余应力与钻孔结果的一致性达到96%，验证了这两种方法。

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引用次数: 0

Process parameter optimization and bonding mechanism in dissimilar S45C/A6061 joints via novel sacrificing-sheet linear friction welding 新型牺牲片线性摩擦焊接不同S45C/A6061接头的工艺参数优化及连接机理

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-07-16 DOI: 10.1016/j.jajp.2025.100331

Furkan Khan, Takuya Miura, Yoshiaki Morisada, Kohsaku Ushioda, Hidetoshi Fujii

Sacrificing-sheet linear friction welding (SSLFW) is a novel solid-state joining technique developed to address the challenges of dissimilar welding between S45C steel and A6061 aluminum alloy, which are difficult to join using conventional linear friction welding (LFW). In this method, a S45C center sheet is linearly oscillated while the two base materials, i.e., S45C and A6061, are pressed against it using a center-driven double-sided LFW machine. The center sheet acts as a sacrificial sheet, which is progressively expelled from the joint interface during welding owing to thermomechanical effect from each side, thereby enabling direct joining between the base materials. This study investigates the effects of key process parameters on mechanical properties and interfacial microstructure, and clarifies the bonding mechanism of SSLFW. Optimum welding conditions with 2 mm upset length, 300 MPa applied pressure toward A6061, 1 s preheat time, and 50 MPa preheat pressure produced sound, defect-free joints with a thin, continuous intermetallic compound (IMC) layer of approximately 100 nm. These conditions enabled simultaneous plastic deformation of both base materials through sacrificing role of center sheet and effective suppression of unbonded regions. The resulting as-welded joint achieved a peak tensile strength of ∼235.3 MPa, corresponding to a joint efficiency of ∼73 % with respect to the A6061 base metal. Post-weld artificial aging significantly exhibited hardness recovery on the A6061 side, enhancing the joint strength to ∼307 MPa and increasing joint efficiency to ∼96 %. These results demonstrate the high potential of SSLFW for sound dissimilar metal joining.

牺牲片线性摩擦焊是为了解决传统线性摩擦焊难以连接的S45C钢与A6061铝合金异种焊接而发展起来的一种新型固态连接技术。该方法利用中心驱动的双面LFW机对S45C中心片材进行线性振荡，同时对S45C和A6061两种基材进行压制。中心片作为牺牲片，在焊接过程中，由于两侧的热机械效应，牺牲片逐渐从连接界面中排出，从而实现基材之间的直接连接。研究了关键工艺参数对SSLFW力学性能和界面微观组织的影响，阐明了SSLFW的结合机理。最佳焊接条件为镦距2mm， A6061施加压力300 MPa，预热时间1 s，预热压力50 MPa，可产生具有约100 nm薄的连续金属间化合物（IMC）层的良好无缺陷接头。在这些条件下，通过牺牲中心片的作用和有效抑制非粘合区域，使两种基材同时发生塑性变形。由此产生的焊接接头的峰值抗拉强度为~ 235.3 MPa，相对于A6061母材的接头效率为~ 73%。焊后人工时效显著恢复了A6061侧的硬度，使接头强度提高到~ 307 MPa，接头效率提高到~ 96%。这些结果表明，SSLFW在声学异种金属连接方面具有很高的潜力。

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引用次数: 0

Comparative evaluation of conventional friction stir welding and ultrasonic vibration-assisted friction stir welding techniques 传统搅拌摩擦焊与超声振动辅助搅拌摩擦焊技术的对比评价

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-07-08 DOI: 10.1016/j.jajp.2025.100330

Noah E. El-Zathry , Rasheedat M. Mahamood , Wai Lok Woo , Sarah Green , Stephen Akinlabi , Naveen Loganathan , Vivek Patel

Enhancing joint strength in aluminium alloys remains a critical challenge for industrial applications. Friction stir welding (FSW) is a solid-state welding process that offers superior weld quality compared to fusion methods. However, further advancements are needed, particularly for high-performance alloys like third-generation Al-Li. To address this, ultrasonic vibration-assisted FSW (UVaFSW) has been explored as a potential enhancement. This study compares the mechanical and microstructural properties of AA2060-T8-E30 joints produced by FSW and UVaFSW. Key process parameters, including tool traverse speed and ultrasonic vibration amplitude (7.5 µm and 22.5 µm), were varied to assess their influence on weld quality. Mechanical performance was evaluated through tensile testing and Vickers microhardness, while microstructural characteristics were examined using optical microscopy and SEM. The results demonstrated that UVaFSW significantly improved material flow, reduced asymmetry in the thermo-mechanically affected zone (TMAZ), and refined the grain structure. Consequently, the ultimate tensile strength increased by 16.6 % and 31.8 % at 7.5 µm and 22.5 µm amplitudes, respectively, and elongation reached 11 %, nearly three times that of FSW. Furthermore, UVaFSW produced finer grains and more uniform precipitate distribution. Therefore, UVaFSW emerges as a promising technique for enhancing weld quality in advanced Al-Li alloys for demanding engineering applications.

提高铝合金的接头强度仍然是工业应用的关键挑战。搅拌摩擦焊（FSW）是一种固态焊接工艺，与熔合方法相比，它提供了更好的焊接质量。然而，需要进一步的进步，特别是像第三代铝锂合金这样的高性能合金。为了解决这个问题，超声波振动辅助FSW （UVaFSW）作为一种潜在的增强技术被探索。本研究比较了FSW和UVaFSW制备的AA2060-T8-E30接头的力学性能和显微组织性能。改变关键工艺参数，包括刀具横移速度和超声振幅（7.5µm和22.5µm），以评估它们对焊接质量的影响。通过拉伸测试和维氏显微硬度评估其力学性能，并通过光学显微镜和扫描电镜检查其显微组织特征。结果表明，UVaFSW显著改善了材料流动，减少了热机械影响区（TMAZ）的不对称性，并细化了晶粒结构。在7.5µm和22.5µm幅值下，拉伸强度分别提高了16.6%和31.8%，伸长率达到11%，几乎是FSW的3倍。此外，UVaFSW产生更细的晶粒和更均匀的沉淀分布。因此，UVaFSW成为一种很有前途的技术，可以提高高要求工程应用中先进铝锂合金的焊接质量。

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引用次数: 0

Effect of bonding temperature on microstructure and mechanical properties of TLP-bonded Ti-6Al-4V/Inconel 718 joints using BNi2/Cu interlayer 结合温度对BNi2/Cu夹层Ti-6Al-4V/Inconel 718 tlp结合接头组织和力学性能的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-07-06 DOI: 10.1016/j.jajp.2025.100328

Sepehr Pourmorad Kaleybar, Hamid Khorsand

The joining of Ti-6Al-4 V to Inconel 718 is notable in industries. This research studied the effect of bonding temperatures (800, 850, 900, 950, and 1000 °C) on properties of Ti-6Al-4 V and Inconel 718 joints using BNi2/Cu interlayer in TLP bonding. The samples were analyzed for their microstructure and mechanical properties using a range of techniques: optical microscopy (OM), scanning electron microscope (SEM), X-ray diffraction (XRD), microhardness testing, shear strength evaluation, and high-temperature shear tests. Microstructural analysis indicated the formation of intermetallic compounds like Ti2Cu, Ti₂Ni, NiTi, and Ni₃Ti within the diffusion-affected zone (DAZ) and solidification zone (SZ) of the TLP-bonded samples. The results demonstrated that temperature had a profound impact on the microstructure of the TLP-bonded samples; specifically, the width of the solidification zone increased as the TLP temperature rose. Moreover, there was an optimal temperature for achieving superior mechanical properties. For instance, a shear strength of 399.75 MPa was achieved at 950 °C as the highest shear strength value. The findings also revealed that both lower (800 °C) and higher (1000 °C) bonding temperatures led to decreased shear strength due to the presence of porosities and cracks. The high-temperature testing showed suitable mechanical properties for elevated temperatures.

ti - 6al - 4v与Inconel 718的结合在工业中是值得注意的。本研究研究了焊接温度（800、850、900、950和1000℃）对TLP结合中BNi2/Cu中间层ti - 6al - 4v和Inconel 718接头性能的影响。利用光学显微镜（OM）、扫描电镜（SEM）、x射线衍射（XRD）、显微硬度测试、抗剪强度评估和高温剪切测试等一系列技术对样品的微观结构和力学性能进行了分析。显微组织分析表明，在tlp结合试样的扩散影响区（DAZ）和凝固区（SZ）内形成了Ti2Cu、Ti2Ni、NiTi和Ni3Ti等金属间化合物。结果表明：温度对tlp结合样品的微观结构有较大影响；随着TLP温度的升高，凝固区宽度增大。此外，还存在获得优异力学性能的最佳温度。在950℃时抗剪强度最高，达到399.75 MPa。研究结果还表明，较低（800°C）和较高（1000°C）的结合温度都会导致剪切强度下降，这是由于孔隙和裂纹的存在。高温试验表明，该材料在高温下具有良好的力学性能。

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引用次数: 0

The role of pressure in improving the properties of friction welded aluminum–copper dissimilar joints 压力对改善铝铜异种摩擦焊接接头性能的作用

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-07-06 DOI: 10.1016/j.jajp.2025.100329

Riyan Ariyansah , Aditya Rio Prabowo , Nurul Muhayat , Bagus Anang Nugroho , Triyono

Rotary Friction Welding (RFW) is a solid-state joining technique well-suited for dissimilar metals such as aluminum and copper, despite challenges related to differences in electrochemical potential, thermal conductivity, and mechanical properties. While previous studies have explored the influence of process parameters on joint quality, limited attention has been given to the systematic optimization of axial pressure in relation to intermetallic compound (IMC) formation and mechanical performance. This study investigates the effect of varying axial pressures (20, 30, and 40 kg/cm²) on the microstructure and mechanical behavior of rotary friction-welded joints between 6061 aluminum and pure copper. The welding parameters, including rotational speed (1300 rpm), friction time (45 s), and pressure time (30 s), were held constant to isolate the effect of pressure. Macro and microstructural analyses, along with hardness and tensile testing, were conducted. The results show that axial pressure significantly influences the morphology and thickness of IMCs formed in the central weld zone (CWZ), thereby affecting joint strength. Notably, a friction pressure of 20 kg/cm² was found to be optimal, yielding the highest combination of hardness and tensile strength compared to other specimens, thus demonstrating a good balance between metallurgical bonding and mechanical performance. Compared to similar studies, this work demonstrates improved mechanical performance at a lower IMC thickness, highlighting the importance of pressure optimization in balancing metallurgical bonding with mechanical integrity. The novelty of this research lies in identifying the critical role of pressure in tailoring IMC development and optimizing joint strength for aluminum-copper dissimilar metal welding.

旋转摩擦焊（RFW）是一种固态焊接技术，非常适合于不同的金属，如铝和铜，尽管存在与电化学电位、导热性和机械性能差异相关的挑战。虽然以往的研究探讨了工艺参数对接头质量的影响，但对轴向压力与金属间化合物（IMC）形成和力学性能之间的关系的系统优化关注有限。研究了不同轴向压力（20、30和40 kg/cm²）对6061铝与纯铜旋转摩擦焊接接头组织和力学行为的影响。焊接参数保持恒定，包括转速（1300转/分）、摩擦时间（45秒）和压力时间（30秒），以隔离压力的影响。进行了宏观和微观组织分析，以及硬度和拉伸测试。结果表明：轴向压力对中心焊缝区imc的形貌和厚度有显著影响，从而影响接头强度；值得注意的是，与其他样品相比，20 kg/cm²的摩擦压力是最佳的，可以产生最高的硬度和抗拉强度组合，从而证明了冶金结合和机械性能之间的良好平衡。与类似的研究相比，这项工作表明，在较低的IMC厚度下，机械性能得到改善，突出了压力优化在平衡冶金结合与机械完整性方面的重要性。本研究的新颖之处在于确定了压力在铝铜异种金属焊接中定制IMC发展和优化接头强度的关键作用。

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引用次数: 0

Microstructure and mechanical properties of ethylene pyrolysis furnace tube weld joints after service 乙烯热解炉管焊缝使用后的组织与力学性能

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-06-28 DOI: 10.1016/j.jajp.2025.100327

Jingfeng Guo , Xiangping Guo , Xiaoyu Li , Guobing Hu , Wenwen Liu

The microstructure and mechanical properties of weld joints in ethylene pyrolysis furnace (Cr25Ni35NbM alloy and Cr35Ni45NbM alloy tube) after service were investigated in this work. The microstructure of the new weld joint and base metal of pyrolysis furnace tube vary widely, and the high temperature creep rupture time of the weld joint is only reached 50% of the base metal (1100°C, 16MPa). After high-temperature service, the microstructure of weld metal and base metal deteriorated and the high temperature creep strength decreased. Therefore, the microstructure of weld metal and base metal is tend to uniform, and the creep strength of weld joint and base metal reached the same level. After high-temperature aging, the primary carbides coarsen and secondary carbides precipitation results in a uniform microstructure and creep property of weld metal and base metal. The high temperature creep rupture time of weld joint reached 90% of base metal (1100°C, 16MPa). As the dispersion strengthening effect of the secondary carbide disappears, the creep strength of the weld joint no longer increases, but begins to decrease. Both high temperature service and elevated temperature aging result in the homogenization of the weld joint and base metal, and the high-temperature creep strength also reaches the same level.

对乙烯热解炉（Cr25Ni35NbM合金和Cr35Ni45NbM合金管）使用后的焊缝组织和力学性能进行了研究。新型热分解炉管焊缝接头与母材显微组织差异较大，焊缝接头高温蠕变断裂时间仅达到母材的50%（1100℃，16MPa）。高温使用后，焊缝金属和母材组织变质，高温蠕变强度下降。因此，焊缝金属和母材的显微组织趋于均匀，焊缝接头和母材的蠕变强度达到同一水平。高温时效后，初生碳化物粗化，次生碳化物析出，焊缝金属与母材组织和蠕变性能均匀。焊缝高温蠕变断裂时间达到母材的90%（1100℃，16MPa）。随着二次碳化物弥散强化作用的消失，焊缝的蠕变强度不再增加，而是开始降低。高温使用和高温时效均使焊缝与母材均质化，高温蠕变强度达到相同水平。

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引用次数: 0

Friction stir welding tool trajectory error on the load capacity of EN AW-2024-T3 aluminum alloy joints 搅拌摩擦焊刀具轨迹误差对EN AW-2024-T3铝合金接头承载能力的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-06-27 DOI: 10.1016/j.jajp.2025.100325

Magdalena Bucior , Rafał Kluz , Andrzej Kubit , Hamed Aghajani Derazkola , Enrico Cestino , Ján Slota

This study investigates the influence of tool trajectory deviations on the load capacity and material flow of friction stir welded (FSW) overlap joints made of EN AW-2024-T3 aluminum alloy. Given that robotic movement is inherently burdened with deviation errors from a theoretically linear trajectory, this study aimed to assess the impact of these deviations on weld quality. Since the FSW-capable robot has low stiffness, a HAAS TM1P milling machine was used to simulate the robot's motion, incorporating recorded deviation errors. The welding process of 1 mm thick sheets was first conducted under ideal rectilinear conditions, establishing optimal parameters: feed rate of 200 mm/min, tool rotational speed of 1517 rpm, and plunge depth of 1.46 mm. Subsequently, controlled trajectory errors with standard deviations ranging from 0.05 mm to 0.2 mm were introduced into the milling machine’s movement to replicate robotic deviation. The results indicate that trajectory deviations with a standard deviation of up to 0.1 mm do not significantly affect the load capacity (increase from 1.01% to 1.95%) but increase dispersion in mechanical performance (2.22% - 2.5%). SEM analysis revealed that when trajectory errors exceeded 0.15 mm, material folding and microcracks appeared, compromising weld integrity. Furthermore, multi-criteria optimization demonstrated that compensating for trajectory deviations is possible by adjusting welding parameters—specifically, reducing the feed rate to increase heat accumulation. This approach enables the production of welds with a minimal decrease in load capacity (1.55% lower than an ideal trajectory weld), mitigating the negative effects of robotic trajectory errors. The use of a feed rate of x₂ = 296 mm/min and a rotational speed of x₃ = 800 rpm allows for achieving a load capacity of the joints with an average value of 5.36 kN with a standard deviation of σ_F = 0.07 kN.

研究了刀具轨迹偏差对EN AW-2024-T3铝合金搅拌摩擦焊（FSW）重叠接头承载能力和材料流动的影响。鉴于机器人运动本身就有理论上线性轨迹的偏差误差，本研究旨在评估这些偏差对焊接质量的影响。由于具有fsw功能的机器人具有低刚度，因此使用HAAS TM1P铣床模拟机器人的运动，并结合记录的偏差误差。首先在理想直线条件下进行了1 mm厚薄板的焊接工艺，确定了最佳参数：进给速度为200 mm/min，刀具转速为1517 rpm，插入深度为1.46 mm。随后，在铣床的运动中引入标准偏差为0.05 mm至0.2 mm的可控轨迹误差，以复制机器人的偏差。结果表明，当轨迹偏差达到0.1 mm标准时，对承载能力的影响不显著（从1.01%增加到1.95%），但会增加机械性能的分散性（从2.22%增加到2.5%）。SEM分析表明，当轨迹误差超过0.15 mm时，会出现材料折叠和微裂纹，影响焊缝的完整性。此外，多准则优化表明，可以通过调整焊接参数来补偿轨迹偏差，特别是通过降低进给速度来增加热量积累。这种方法使焊缝的承载能力下降最小（比理想轨迹焊缝低1.55%），减轻了机器人轨迹误差的负面影响。当进给速度x2 = 296 mm/min，转速x3 = 800 rpm时，接头的承载能力平均值为5.36 kN，标准差为σF = 0.07 kN。

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引用次数: 0

Influence of the pin diameter to spacing ratio in metal/composite joints joined via metallic pin structures 金属销结构连接金属/复合材料接头销径与间距比的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-06-24 DOI: 10.1016/j.jajp.2025.100326

Julian Popp , Jan Gavelek , David Römisch , Marion Merklein , Dietmar Drummer

Joining metal components with thermoplastic composites via the embedding of pin structures is a promising novel mechanical joining technology to create lightweight hybrid components. In the current state of the art, it is not understood which influence the pin size and pin arrangement in a multi pin array has on the mechanical performance of the created joints. In the scope of the present study different pin arrays have been used to create joints between stainless steel and unidirectionally reinforced thermoplastic composites. Thereby the pin density, which describes the fraction of the joint surface is occupied by pin structures, in the joint is kept constant and the pin size and pin arrangement has been varied. It shows that a higher number of smaller pins leads to better mechanical performance under both shear as well as normal testing load. Furthermore, an asymmetric pin arrangement, where one out of two pin rows is offset perpendicular to the fiber orientation, increased joint strength. The achieved shear strength of the samples reaches up to 10.8 MPa while the achieved normal strength is significantly lower at a maximum of 2.3 MPa.

通过嵌入销钉结构将金属部件与热塑性复合材料连接是一种很有前途的新型机械连接技术，可用于制造轻质混合材料部件。在目前的技术状态下，尚不了解多针阵列中的针尺寸和针排列对所创建的关节的机械性能的影响。在本研究的范围内，不同的引脚阵列被用于在不锈钢和单向增强热塑性复合材料之间建立连接。因此，描述销结构在连接表面所占比例的销密度在连接中保持不变，而销的尺寸和销的排列却发生了变化。结果表明，无论在剪切荷载下还是在正常荷载下，小销数量越多，结构的力学性能越好。此外，不对称针的排列，其中两排针中的一排垂直于纤维方向偏移，增加了接头强度。试样的抗剪强度达到10.8 MPa，而法向强度较低，最大为2.3 MPa。

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引用次数: 0

Effect of Mg-rich filler metal on weld zone properties in pulsed laser-welded ultra-fine grain AA6061: A Taguchi optimization study 富镁填充金属对脉冲激光焊接超细晶粒AA6061焊缝区性能影响的田口优化研究

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-06-18 DOI: 10.1016/j.jajp.2025.100323

S. Karami , M.H. Siadati , M. Yousefieh

This study investigates the effects of filler metal with high magnesium (Mg) content at different heat inputs on microstructural evolution, strengthening mechanisms, and reduction of welding defects in pulsed laser welding (PLW) of ultra-fine-grained (UFG) AA6061 sheets. The dominant mechanism in UFG-welded AA6061 specimens, produced by accumulative roll bonding (ARB), was attributed to the grain boundary strengthening (GBS) effect due to grain size reduction and an increase in dislocation density. High heat input and remelting during PLW with AA5356 filler destroy the UFG structure, causing grain growth in the heat-affected zone (HAZ) and weld zone (WZ). It is shown that weld No. 7, with a heat input of 112 J/mm, and the use of high Mg filler metal contributed to the improvement of WZ strength due to increased fluidity, uniform distribution of this alloying element, and precipitation of Mg₂Si strengthening phase in the WZ. After welding under optimal conditions using a filler metal along with high Mg content, the strengthening mechanisms changed from the GBS effect and increased dislocation density to solid solution strengthening and precipitation of Mg₂Si as the strengthening phase. Scanning electron microscopy images show that laser welding using AA5356 filler metal eliminates the delamination effect and local necking, which are the leading causes of AA6061-UFGed failure. The failure in weld No. 7 indicates ductile fracture due to the heterogeneous distribution of dimples.

研究了高镁填充金属在不同热输入下对超细晶AA6061薄板脉冲激光焊接（PLW）过程中组织演变、强化机制和减少焊接缺陷的影响。累积轧制结合（ARB）产生的AA6061 ufg焊接试样的主要机制是晶粒尺寸减小和位错密度增加所导致的晶界强化（GBS）效应。在填充AA5356的PLW过程中，高热量输入和重熔破坏了UFG组织，导致热影响区（HAZ）和焊缝区（WZ）晶粒长大。结果表明：热输入为112 J/mm的7号焊缝和高Mg钎料金属的加入，提高了焊缝的流动性，使合金元素分布均匀，并在焊缝中析出Mg2Si强化相，从而提高了焊缝的强度。在最佳焊接条件下使用高Mg含量的钎料焊接后，强化机制由GBS效应和位错密度增加转变为以Mg2Si为强化相的固溶强化和析出强化。扫描电镜图像显示，采用AA5356填充金属的激光焊接消除了导致AA6061-UFGed失效的主要原因分层效应和局部缩颈。由于韧窝分布不均，7号焊缝为韧性断裂。

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