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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 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 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 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 σF = 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 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 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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引用次数: 0
Enhancing the performance of double-flush riveted joints through hybridization with adhesive bonding 通过与胶粘接的杂交,提高双平头铆接接头的性能
IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY Pub Date : 2025-06-18 DOI: 10.1016/j.jajp.2025.100324
João M.B. Alpendre , 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 the potential to enhance the mechanical performance of joints created through a new joining-by-forming technique called hybrid double-flush riveting. To achieve this, adhesive bonding is used to form hybrid lap joints with superior mechanical properties. The study focuses on high-strength steel sheets and starts by identifying the appropriate surface conditions necessary for producing strong adhesive-bonded joints. A similar strategy is applied to construct double-flush riveted joints, focusing on the geometric variables involved in the process. Hybrid joints are then created by integrating adhesive bonding with double-flush riveting, with the second carried out before or after curing is completed. The experimental development is supported by finite element analysis conducted with an in-house computer program.
The mechanical performance of the hybrid joints is compared to that of purely adhesive-bonded and conventionally double-flush riveted joints through shear and peel destructive testing. Results demonstrate that hybrid joints ultimately provide greater joint strength for both solicitations. This allows showcasing the hybridization of double-flush riveting with adhesive bonding as an effective solution for applications where joint strength and continuity are essential.
本文探讨了通过一种称为混合双冲铆接的新型成形连接技术来提高接头机械性能的潜力。为了实现这一点,使用粘合剂粘合形成具有优越机械性能的混合搭接。该研究的重点是高强度钢板,并从确定生产强粘合剂粘合接头所需的适当表面条件开始。一个类似的策略应用于构建双冲铆接接头,重点是在过程中涉及的几何变量。然后通过将胶粘接与双侧铆接相结合来创建混合接头,第二次铆接在固化完成之前或之后进行。实验开发由内部计算机程序进行的有限元分析支持。通过剪切和剥离破坏试验,将混合接头的力学性能与纯胶粘接和常规双冲铆接进行了比较。结果表明,混合节理最终为两种工况提供了更高的节理强度。这可以展示双冲铆与粘合剂粘合的杂交,作为接缝强度和连续性至关重要的应用的有效解决方案。
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引用次数: 0
Thermo mechanical Finite Element Analysis of the plasma Wire Arc Additive Manufacturing process in DEFORM® 13 DEFORM®13中等离子丝弧增材制造过程的热机械有限元分析
IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY Pub Date : 2025-06-16 DOI: 10.1016/j.jajp.2025.100321
Marcel Czipin, Alexander Wenda, Karin Hartl, Emre Akalin, Martin Stockinger
This study investigates the potential of Finite Element Analysis in DEFORM® to predict the thermal history, deformation, residual stress state and grain growth in the Wire Arc Additive Manufacturing processes of Ti–6Al–4V. The temperature dependent material model for Ti–6Al–4V was extended and adapted to improve the representation of contact boundary conditions within DEFORM®, focusing on Additive Manufacturing. A single layer quad-mesh approach was employed alongside dummy heat sources to simulate the process by accurate layer wise activation within the arc welding module. The model utilized a normalized double-ellipsoid heat source and introduced a power adaptation strategy to account for differences in volumetric deposition. The extracted thermal history showed very good agreement to corresponding thermocouple measurements. The accuracy of the resulting deformation state was validated using a 3D scan, while the predicted grain size distribution was compared against an as-built micrograph. The simulation showed good overall accuracy, though limitations were noted in the grain size model, which was inadequate in predicting the more complex texture of the mixed α/β-microstructure typical for Ti–6Al–4V. Seven heat treatment strategies were evaluated to address mechanical anisotropy. Solution annealing followed by water quenching and subsequent low temperature aging was found to be most effective.
本研究探讨了DEFORM®有限元分析在预测Ti-6Al-4V电弧增材制造过程中的热历史、变形、残余应力状态和晶粒生长方面的潜力。Ti-6Al-4V的温度相关材料模型进行了扩展和调整,以改善DEFORM®中接触边界条件的表示,重点是增材制造。采用单层四网格方法与虚拟热源一起,通过在弧焊模块内精确分层激活来模拟过程。该模型采用归一化双椭球热源,并引入功率自适应策略来考虑体积沉积的差异。提取的热历史与相应的热电偶测量结果非常吻合。通过3D扫描验证了变形状态的准确性,同时将预测的晶粒尺寸分布与构建的显微照片进行了比较。尽管晶粒尺寸模型存在一定的局限性,不足以预测Ti-6Al-4V混合α/β-组织的复杂织构,但模拟结果总体精度较高。评估了7种热处理策略以解决机械各向异性问题。溶液退火后再进行水淬和低温时效是最有效的。
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引用次数: 0
Prediction of weld quality in laser welding of hardmetal and steel using high-speed imaging and machine learning methods 基于高速成像和机器学习方法的硬质合金和钢激光焊接焊缝质量预测
IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY Pub Date : 2025-06-01 DOI: 10.1016/j.jajp.2025.100318
Mohammadhossein Norouzian , Mahan Khakpour , Marko Orosnjak , Atal Anil Kumar , Slawomir Kedziora
Laser welding of steel and hardmetal presents significant challenges due to their differing material properties. Improper laser welding parameters can result in unstable joints, ultimately leading to reduced mechanical strength of the weld. Therefore, defining an optimal process window is critical to ensuring weld quality. In addition, a continuous process monitoring method like High-Speed Imaging (HSI) is essential in real industrial applications to maintain stability and detect potential defects. Understanding plume dynamics helps identify the most important features of weld quality, but it also provides deeper insight into operational parameters that discriminate different weld types. Analysis of individual image plume frames from HSI reveals distinct statistical features that are identified as unique to each welding condition. Performing systematic feature selection using plume morphology, spatter generation and weld quality, we achieved>95 % leveraging Machine Learning (ML) classifiers. Particularly, Gradient Boosting Classifier (GBC), Linear Discriminant Analysis (LDA), Multinomial Logistic Regression (MNL-LR), Support Vector Machine (SVM), and Random Forest (RF), where the RF obtained >99 % classification accuracy of weld quality. The RF was then used in performing Recursive Feature Elimination (RFE), and with the robustness analysis, we managed to reduce the number of features from forty-nine to nine features while maintaining satisfactory performance (Accuracy = 0.981, F1-score = 0.961, AUROC = 0.997). The position of the weld plume, plume eccentricity and plume width are the most essential features that lead to the improvement of node purity and classification accuracy.
钢和硬质合金的激光焊接由于其不同的材料特性而面临着巨大的挑战。不当的激光焊接参数会导致接头不稳定,最终导致焊缝机械强度降低。因此,确定最佳工艺窗口对于确保焊接质量至关重要。此外,在实际工业应用中,像高速成像(HSI)这样的连续过程监控方法对于保持稳定性和检测潜在缺陷至关重要。了解羽流动力学有助于确定焊接质量的最重要特征,同时也有助于更深入地了解区分不同焊接类型的操作参数。对HSI中单个图像羽流帧的分析揭示了不同的统计特征,这些特征被认为是每个焊接条件所独有的。利用羽流形态、飞溅产生和焊接质量进行系统的特征选择,我们利用机器学习(ML)分类器实现了95%的目标。特别是梯度增强分类器(GBC)、线性判别分析(LDA)、多项逻辑回归(MNL-LR)、支持向量机(SVM)和随机森林(RF),其中RF对焊缝质量的分类准确率达到99%。然后使用RF进行递归特征消除(RFE),通过鲁棒性分析,我们成功地将特征数量从49个减少到9个,同时保持令人满意的性能(精确度= 0.981,F1-score = 0.961, AUROC = 0.997)。焊缝羽流位置、羽流偏心率和羽流宽度是提高节点纯度和分类精度的最基本特征。
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引用次数: 0
Corrigendum to “Exploring Wire-Arc Additive Manufactured Rivets for Joining Hybrid Electrical Busbars” “探索用于连接混合电母线的线弧添加剂制造铆钉”的勘误表
IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY Pub Date : 2025-06-01 DOI: 10.1016/j.jajp.2025.100291
Pedro M.S. Rosado , Rui F.V. Sampaio , João P.M. Pragana , Nuno M.S. Pereira , Ivo M.F. Bragança , Carlos M.A. Silva , Paulo A.F. Martins
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引用次数: 0
Enhancement of mechanical properties of thermite heat assisted friction stir welded aluminium bronze alloy (C95300) by eliminating tunnel defect 消除隧道缺陷提高铝热辅助搅拌摩擦焊铝青铜合金(C95300)的力学性能
IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY Pub Date : 2025-06-01 DOI: 10.1016/j.jajp.2025.100317
Tamil Prabakaran S , Sudha J , Siva S , Balamurali Duraivel , Vivekananda A S
Thermite Heat-Assisted Friction Stir Welding (THAFSW) is recognized as an efficient welding method for joining aluminium bronze (AB) alloys. The mechanical and metallurgical characteristics of the welded joints were analyzed and compared with those fabricated using the conventional friction stir welding (CFSW) technique. Tensile strength and hardness assessments of the welded specimens were conducted at ambient temperature. The findings revealed that the THAFSW joints exhibited superior mechanical properties, with tensile strength and elongation improving by 11 % and 25 %, respectively, compared to joints produced through the conventional approach. The strengthening mechanism of the welded joints was examined based on images captured through macroscopy, optical microscopy, scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The THAFSW process effectively eliminated tunnel defects and facilitated the development of a uniform α-phase microstructure, which contributed to enhanced mechanical performance.
铝热剂热辅助搅拌摩擦焊(THAFSW)被认为是连接铝青铜(AB)合金的一种有效的焊接方法。对焊接接头的力学和冶金特性进行了分析,并与传统搅拌摩擦焊(CFSW)工艺进行了比较。焊接试样的抗拉强度和硬度评估在室温下进行。研究结果表明,与传统方法生产的接头相比,THAFSW接头具有优越的机械性能,抗拉强度和伸长率分别提高了11%和25%。通过宏观显微镜、光学显微镜、扫描电镜和透射电镜对焊接接头的强化机理进行了研究。THAFSW工艺有效地消除了隧道缺陷,促进了α-相组织的均匀发展,从而提高了材料的力学性能。
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引用次数: 0
期刊
Journal of Advanced Joining Processes
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