Pub Date : 2025-06-01Epub Date: 2025-02-28DOI: 10.1016/j.jajp.2025.100298
H. Bakhtiari , M. Farvizi , M.R. Rahimipour , A. Malekan
This study investigates the hot corrosion behavior of transient liquid phase (TLP) bonding in Hastelloy X (HX) subjected to a molten salt environment of Na2SO4–V2O5 at 900°C, examining various bonding times of 5, 20, 80, 320, and 640 minutes. The samples were bonded at 1070°C, and their corrosion products along with microstructural features were examined. The microstructural analysis confirmed the presence of primary eutectic phases in the joints, including Ni-rich borides and silicides, Ni-Si eutectics, and several chromium-rich borides. Samples bonded for 20 and 80 min showed inferior hot corrosion resistance. Conversely, the sample that was bonded for 320 minutes exhibited improved resistance because of a more uniform distribution of alloy elements and lower boride concentrations at the interface. During the hot corrosion tests, initially, the TLP surface is covered by a dense Cr2O3 and NiO layer. After 20 h of hot corrosion, due to the reaction of oxide layers with vanadium, NaVO3 forms, while sulfur diffusion leads to the evolution of internal sulfides based on Ni, Cr, and Mo. The presence of NaVO3 and SO3, along with the reduction of Cr2O3, significantly affects the hot corrosion resistance over prolonged exposure.
{"title":"Hot corrosion mechanism in transient liquid phase bonded HX superalloy: Effect of bonding time","authors":"H. Bakhtiari , M. Farvizi , M.R. Rahimipour , A. Malekan","doi":"10.1016/j.jajp.2025.100298","DOIUrl":"10.1016/j.jajp.2025.100298","url":null,"abstract":"<div><div>This study investigates the hot corrosion behavior of transient liquid phase (TLP) bonding in Hastelloy X (HX) subjected to a molten salt environment of Na<sub>2</sub>SO<sub>4</sub>–V<sub>2</sub>O<sub>5</sub> at 900°C, examining various bonding times of 5, 20, 80, 320, and 640 minutes. The samples were bonded at 1070°C, and their corrosion products along with microstructural features were examined. The microstructural analysis confirmed the presence of primary eutectic phases in the joints, including Ni-rich borides and silicides, Ni-Si eutectics, and several chromium-rich borides. Samples bonded for 20 and 80 min showed inferior hot corrosion resistance. Conversely, the sample that was bonded for 320 minutes exhibited improved resistance because of a more uniform distribution of alloy elements and lower boride concentrations at the interface. During the hot corrosion tests, initially, the TLP surface is covered by a dense Cr<sub>2</sub>O<sub>3</sub> and NiO layer. After 20 h of hot corrosion, due to the reaction of oxide layers with vanadium, NaVO<sub>3</sub> forms, while sulfur diffusion leads to the evolution of internal sulfides based on Ni, Cr, and Mo. The presence of NaVO<sub>3</sub> and SO<sub>3</sub>, along with the reduction of Cr<sub>2</sub>O<sub>3</sub>, significantly affects the hot corrosion resistance over prolonged exposure.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100298"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143580239","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Friction Stir Welding (FSW) is a significant solid-state joining technique for metals and polymers, effectively addressing challenges posed by fusion welding. The application of FSW relies on the development of cost-effective, durable tools that consistently produce high-quality welds. The forces and torque generated during welding are critical to this process, which influence weld integrity, process efficiency, and tool longevity. This review explores methodologies for estimating these parameters—analytical, numerical, and experimental—and discusses measurement techniques, including direct and indirect methods. It also examines variations in forces across different FSW types, such as Conventional FSW, Bobbin Tool FSW, and Stationary Shoulder FSW, emphasizing the differences in their operational mechanics. Additionally, the review highlights how process parameters like tool shape, size, tilt angle, and welding speed can be optimized to enhance performance and investigates the use of force measurements for real-time weld monitoring and defect detection, contributing to the reliability of FSW in industrial applications. The results indicate that the use of force measurement for online monitoring of welding processes, particularly concerning welding defects and overall weld quality, has garnered significant attention in recent years. A notable advancement in this field is the implementation of machine learning tools, which enhance the ability to predict potential weld defects and improve overall weld quality. This innovative approach not only streamlines the monitoring process but also contributes to the evolution of FSW technologies, ensuring higher standards of quality and safety in various applications.
{"title":"The role of force and torque in friction stir welding: A detailed review","authors":"Mostafa Akbari , Milad Esfandiar , Amin Abdollahzadeh","doi":"10.1016/j.jajp.2025.100289","DOIUrl":"10.1016/j.jajp.2025.100289","url":null,"abstract":"<div><div>Friction Stir Welding (FSW) is a significant solid-state joining technique for metals and polymers, effectively addressing challenges posed by fusion welding. The application of FSW relies on the development of cost-effective, durable tools that consistently produce high-quality welds. The forces and torque generated during welding are critical to this process, which influence weld integrity, process efficiency, and tool longevity. This review explores methodologies for estimating these parameters—analytical, numerical, and experimental—and discusses measurement techniques, including direct and indirect methods. It also examines variations in forces across different FSW types, such as Conventional FSW, Bobbin Tool FSW, and Stationary Shoulder FSW, emphasizing the differences in their operational mechanics. Additionally, the review highlights how process parameters like tool shape, size, tilt angle, and welding speed can be optimized to enhance performance and investigates the use of force measurements for real-time weld monitoring and defect detection, contributing to the reliability of FSW in industrial applications. The results indicate that the use of force measurement for online monitoring of welding processes, particularly concerning welding defects and overall weld quality, has garnered significant attention in recent years. A notable advancement in this field is the implementation of machine learning tools, which enhance the ability to predict potential weld defects and improve overall weld quality. This innovative approach not only streamlines the monitoring process but also contributes to the evolution of FSW technologies, ensuring higher standards of quality and safety in various applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100289"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143350466","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-06-02DOI: 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.
{"title":"Prediction of weld quality in laser welding of hardmetal and steel using high-speed imaging and machine learning methods","authors":"Mohammadhossein Norouzian , Mahan Khakpour , Marko Orosnjak , Atal Anil Kumar , Slawomir Kedziora","doi":"10.1016/j.jajp.2025.100318","DOIUrl":"10.1016/j.jajp.2025.100318","url":null,"abstract":"<div><div>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.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100318"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144194641","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}
Friction stir welding has demonstrated significant efficacy as a solid-state welding methodology for aluminum alloys, including AA6061-T6, and is extensively utilized within automotive and aerospace engineering domains. Nonetheless, conventional FSW methods often lead to uneven residual stress distributions, compromising the material's resistance to fatigue cracking. Simultaneous Double-sided Friction Stir Welding (SDFSW) was introduced to overcome this limitation, offering enhanced welding quality by welding from both sides. This study examines the influence of tool rotational velocity on the fatigue crack growth and the distribution of residual stresses in the SDFSW process applied to AA6061-T6 aluminum. Several rotational velocity combinations were employed to assess their effect on joint quality, encompassing residual stress distribution and cyclic load performance. Based on previous experiments, the SDFSW process uses upper and lower tool speeds. These are 965/965 rpm, 967/1251 rpm and 965/1555 rpm. Fatigue crack growth testing complied with ASTM E647 standards, and the residual stress distribution was assessed through the X-ray diffraction cos α method. Additional mechanical property assessments were performed, including radiographic analysis, examination of the macrostructure and microstructure, microhardness testing, evaluation of tensile strength, and fracture characterization. The findings reveal that the rotational velocity of the tool significantly impacts the weld zone's microstructure, influencing mechanical properties, residual stress distribution, and crack growth behaviors. Among the tested conditions, the tool's rotational speed of 965/1555 rpm yielded the highest tensile strength of approximately 179.82 MPa, representing about 53 % of the strength of the base material and the greatest microhardness of 85 HV. This velocity combination also demonstrated a low fatigue crack growth rate, with Paris law coefficients C and n measured at 2E-08 and 3.6931, respectively, along with a more favorable residual stress distribution.
{"title":"Fatigue crack growth and residual stress in simultaneous double-sided friction stir welded aluminum alloy AA6061-T6","authors":"Hendrato , Muizuddin Azka , M.Refai Muslih , Rifky Apriansyah , Nidya Jullanar Salman , Sulardjaka , Ilhamdi , Jos Istiyanto , Guino Verma , Andik Dwi Kurniawan , Irfan Ansori , Lukman Shalahuddin , Jean Mario Valentino , Yohanes Pringeten Dilianto Sembiring Depari , Triyono","doi":"10.1016/j.jajp.2025.100300","DOIUrl":"10.1016/j.jajp.2025.100300","url":null,"abstract":"<div><div>Friction stir welding has demonstrated significant efficacy as a solid-state welding methodology for aluminum alloys, including AA6061-T6, and is extensively utilized within automotive and aerospace engineering domains. Nonetheless, conventional FSW methods often lead to uneven residual stress distributions, compromising the material's resistance to fatigue cracking. Simultaneous Double-sided Friction Stir Welding (SDFSW) was introduced to overcome this limitation, offering enhanced welding quality by welding from both sides. This study examines the influence of tool rotational velocity on the fatigue crack growth and the distribution of residual stresses in the SDFSW process applied to AA6061-T6 aluminum. Several rotational velocity combinations were employed to assess their effect on joint quality, encompassing residual stress distribution and cyclic load performance. Based on previous experiments, the SDFSW process uses upper and lower tool speeds. These are 965/965 rpm, 967/1251 rpm and 965/1555 rpm. Fatigue crack growth testing complied with ASTM E647 standards, and the residual stress distribution was assessed through the X-ray diffraction cos α method. Additional mechanical property assessments were performed, including radiographic analysis, examination of the macrostructure and microstructure, microhardness testing, evaluation of tensile strength, and fracture characterization. The findings reveal that the rotational velocity of the tool significantly impacts the weld zone's microstructure, influencing mechanical properties, residual stress distribution, and crack growth behaviors. Among the tested conditions, the tool's rotational speed of 965/1555 rpm yielded the highest tensile strength of approximately 179.82 MPa, representing about 53 % of the strength of the base material and the greatest microhardness of 85 HV. This velocity combination also demonstrated a low fatigue crack growth rate, with Paris law coefficients C and n measured at 2E-08 and 3.6931, respectively, along with a more favorable residual stress distribution.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100300"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143738513","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2024-12-18DOI: 10.1016/j.jajp.2024.100274
Petr Slepička , Klaudia Hurtuková , Silvie Rimpelová , Šárka Trhoňová , Jiří Martan , Michal Procházka , Václav Švorčík , Nikola Slepičková Kasálková
In this study, we investigated the effects of carbon layer deposition on titanium (Ti) and titanium alloy (TiAlV) substrates using "flash" vaporization and pulsed laser deposition (PLD) techniques. Raman spectroscopy revealed that the PLD method produced a higher sp3 carbon bond content than the evaporation method (61 vs. 47 %). Atomic force microscopy and surface wettability analyzes showed differences in surface roughness and contact angle, with PLD-deposited samples exhibiting enhanced hydrophilicity and wrinkled morphology. Subsequent laser annealing optimized surface properties by increasing hydrophobicity, which is critical for cell adhesion. Surface chemistry analysis via scanning electron microscopy and energy dispersive spectroscopy demonstrated significant carbon enrichment in the PLD-deposited samples, mainly for TiAlV substrate. Cytocompatibility tests using human osteosarcoma cells (U-2 OS) revealed varying cell adhesion and proliferation based on surface modification, with PLD-deposited layers promoting better cell interaction. Both carbon deposition techniques enhanced antibacterial effect. This suggests the potential of PLD-deposited carbon layers for biomedical applications, particularly in enhancing implant surfaces for improved cell growth and adhesion, and reduce bacteria, the nanostructured substrates may serve also for subsequent replication process into polymer.
{"title":"Ti and TiAlV foils enhanced with PLD and flash-deposited carbon: On cytocompatibility and antibacterial activity","authors":"Petr Slepička , Klaudia Hurtuková , Silvie Rimpelová , Šárka Trhoňová , Jiří Martan , Michal Procházka , Václav Švorčík , Nikola Slepičková Kasálková","doi":"10.1016/j.jajp.2024.100274","DOIUrl":"10.1016/j.jajp.2024.100274","url":null,"abstract":"<div><div>In this study, we investigated the effects of carbon layer deposition on titanium (Ti) and titanium alloy (TiAlV) substrates using \"flash\" vaporization and pulsed laser deposition (PLD) techniques. Raman spectroscopy revealed that the PLD method produced a higher sp3 carbon bond content than the evaporation method (61 vs<em>.</em> 47 %). Atomic force microscopy and surface wettability analyzes showed differences in surface roughness and contact angle, with PLD-deposited samples exhibiting enhanced hydrophilicity and wrinkled morphology. Subsequent laser annealing optimized surface properties by increasing hydrophobicity, which is critical for cell adhesion. Surface chemistry analysis via scanning electron microscopy and energy dispersive spectroscopy demonstrated significant carbon enrichment in the PLD-deposited samples, mainly for TiAlV substrate. Cytocompatibility tests using human osteosarcoma cells (U-2 OS) revealed varying cell adhesion and proliferation based on surface modification, with PLD-deposited layers promoting better cell interaction. Both carbon deposition techniques enhanced antibacterial effect. This suggests the potential of PLD-deposited carbon layers for biomedical applications, particularly in enhancing implant surfaces for improved cell growth and adhesion, and reduce bacteria, the nanostructured substrates may serve also for subsequent replication process into polymer.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100274"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133082","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-01-10DOI: 10.1016/j.jajp.2025.100282
Hamed Razavi , Hamid Reza Masoumi
This study investigates the impact of ultrasonic vibrations on the press-fitting process, aiming to reduce the maximum press-fit force required in mechanical assemblies. Press-fitting involves inserting a pin into a bushing of a slightly smaller diameter, leading to high press-fit forces, which is crucial in the analysis and performance assessment of the process. The research investigates the effects of assembly speed and ultrasonic vibration power on the reduction of press-fit force. Through a series of 15 distinct experiments employing both conventional press-fitting (CPF) and ultrasonic-assisted press-fitting (UAPF), it was found that increasing the power of ultrasonic vibrations leads to a significant decrease in the maximum press-fit force, whereas reducing the assembly speed has a minor effect. The maximum press-fit force is reduced by over 80 % when utilizing maximum vibration power. The findings indicate that the UAPF method is a promising technique to reduce the maximum press-fit force, thus improving the feasibility of the press-fitting process. This research has significant implications for the manufacturing industry, enabling the assembly of sensitive parts without excessive force and improving the overall assembly performance.
{"title":"Ultrasonic-assisted press-fitting: A superior method for reducing press-fit force compared to conventional press-fitting","authors":"Hamed Razavi , Hamid Reza Masoumi","doi":"10.1016/j.jajp.2025.100282","DOIUrl":"10.1016/j.jajp.2025.100282","url":null,"abstract":"<div><div>This study investigates the impact of ultrasonic vibrations on the press-fitting process, aiming to reduce the maximum press-fit force required in mechanical assemblies. Press-fitting involves inserting a pin into a bushing of a slightly smaller diameter, leading to high press-fit forces, which is crucial in the analysis and performance assessment of the process. The research investigates the effects of assembly speed and ultrasonic vibration power on the reduction of press-fit force. Through a series of 15 distinct experiments employing both conventional press-fitting (CPF) and ultrasonic-assisted press-fitting (UAPF), it was found that increasing the power of ultrasonic vibrations leads to a significant decrease in the maximum press-fit force, whereas reducing the assembly speed has a minor effect. The maximum press-fit force is reduced by over 80 % when utilizing maximum vibration power. The findings indicate that the UAPF method is a promising technique to reduce the maximum press-fit force, thus improving the feasibility of the press-fitting process. This research has significant implications for the manufacturing industry, enabling the assembly of sensitive parts without excessive force and improving the overall assembly performance.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100282"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133070","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-02-11DOI: 10.1016/j.jajp.2025.100294
Hesam Mehdikhani , Amir Mostafapour , Behzad Binesh
Naval brass (C46500), due to the presence of tin in this alloy, it exhibits high resistance to atmospheric and aqueous corrosion. This type of brass is widely used in various industries, including marine applications, electrical components, etc. The C70600 copper-nickel alloy, due to the formation of a solid solution, maintains high ductility while increasing tensile strength. High resistance to seawater corrosion, attributed to significant amounts of manganese and iron, are among the key characteristics of this alloy. The joining of these alloys in marine applications are required. Considering the formation of solid solutions and intermetallic compounds and their impact on mechanical properties, controlling their amounts is crucial for achieving optimal results. Brazing is known as an effective method to join these base materials. Since temperature and time are two critical parameters in brazing, influencing the formation of precipitates, this study focuses on optimizing these conditions to achieve desirable microstructural and mechanical properties. The brazing process was performed under 16 different conditions including 650, 680, 710, and 740 °C for 1, 5, 15, and 30 mins. To study the microstructure of joints, and the related phase transformations in the joint region, optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) were used. Mechanical properties of the samples were evaluated through strength testing and micro hardness measurements. The results indicate that with increasing temperature and duration of the joining process, the width of the thermally solidified zone decreases due to the increased diffusion rate, while the width of the isothermal solidification zone increases. Moreover, increasing the brazing time promotes phase segregation. The highest strength, measured at 106.4 MPa, was achieved for the sample joined at 710 °C for 15 mins, with the fracture surface displaying a mixed ductile-brittle mode.
{"title":"Mechanical properties and microstructure of the C70600 copper-nickel alloy and C46500 brass joint using brazing technique","authors":"Hesam Mehdikhani , Amir Mostafapour , Behzad Binesh","doi":"10.1016/j.jajp.2025.100294","DOIUrl":"10.1016/j.jajp.2025.100294","url":null,"abstract":"<div><div>Naval brass (C46500), due to the presence of tin in this alloy, it exhibits high resistance to atmospheric and aqueous corrosion. This type of brass is widely used in various industries, including marine applications, electrical components, etc. The C70600 copper-nickel alloy, due to the formation of a solid solution, maintains high ductility while increasing tensile strength. High resistance to seawater corrosion, attributed to significant amounts of manganese and iron, are among the key characteristics of this alloy. The joining of these alloys in marine applications are required. Considering the formation of solid solutions and intermetallic compounds and their impact on mechanical properties, controlling their amounts is crucial for achieving optimal results. Brazing is known as an effective method to join these base materials. Since temperature and time are two critical parameters in brazing, influencing the formation of precipitates, this study focuses on optimizing these conditions to achieve desirable microstructural and mechanical properties. The brazing process was performed under 16 different conditions including 650, 680, 710, and 740 °C for 1, 5, 15, and 30 mins. To study the microstructure of joints, and the related phase transformations in the joint region, optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) were used. Mechanical properties of the samples were evaluated through strength testing and micro hardness measurements. The results indicate that with increasing temperature and duration of the joining process, the width of the thermally solidified zone decreases due to the increased diffusion rate, while the width of the isothermal solidification zone increases. Moreover, increasing the brazing time promotes phase segregation. The highest strength, measured at 106.4 MPa, was achieved for the sample joined at 710 °C for 15 mins, with the fracture surface displaying a mixed ductile-brittle mode.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100294"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143387546","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-01-21DOI: 10.1016/j.jajp.2025.100284
Wilfried Pacquentin , Pierre Wident , Jérôme Varlet , Thomas Cailloux , Hicham Maskrot
Additive manufacturing (AM) is a proven time- and cost-effective method for repairing parts locally damaged after e.g. repetitive friction wear or corrosion. Repairing a hardfacing coating using AM technologies presents however several simultaneous challenges arising from the complex geometry and a high probability of crack formation due to process-induced stress. We address the repair of a cobalt-based Stellite™ 6 hardfacing coating on an AISI 316L substrate performed using Laser Powder Directed Energy Deposition (LP-DED) and investigate the influence of key process features and parameters. We describe our process which successfully prevents crack formation both during and after the repair, highlighting the design of the preliminary part machining phase, induction heating of an extended part volume during the laser repair phase and the optimal scanning strategy. Local characterization using non-destructive testing, Vickers hardness measurements and microstructural examinations by scanning electron microscopy (SEM) show an excellent metallurgical quality of the repair and its interface with the original part. In addition, we introduce an innovative process qualification test assessing the repair quality and innocuity, which is based on the global response to induced cracks and probes the absence of crack attraction by the repair (ACAR1). Here this ACAR test reveals a slight difference in mechanical behavior between the repair and the original coating which motivates further work to eventually make the repair imperceptible.
{"title":"Temperature influence on the repair of a hardfacing coating using laser metal deposition and assessment of the repair innocuity","authors":"Wilfried Pacquentin , Pierre Wident , Jérôme Varlet , Thomas Cailloux , Hicham Maskrot","doi":"10.1016/j.jajp.2025.100284","DOIUrl":"10.1016/j.jajp.2025.100284","url":null,"abstract":"<div><div>Additive manufacturing (AM) is a proven time- and cost-effective method for repairing parts locally damaged after e.g. repetitive friction wear or corrosion. Repairing a hardfacing coating using AM technologies presents however several simultaneous challenges arising from the complex geometry and a high probability of crack formation due to process-induced stress. We address the repair of a cobalt-based Stellite™ 6 hardfacing coating on an AISI 316L substrate performed using Laser Powder Directed Energy Deposition (LP-DED) and investigate the influence of key process features and parameters. We describe our process which successfully prevents crack formation both during and after the repair, highlighting the design of the preliminary part machining phase, induction heating of an extended part volume during the laser repair phase and the optimal scanning strategy. Local characterization using non-destructive testing, Vickers hardness measurements and microstructural examinations by scanning electron microscopy (SEM) show an excellent metallurgical quality of the repair and its interface with the original part. In addition, we introduce an innovative process qualification test assessing the repair quality and innocuity, which is based on the global response to induced cracks and probes the absence of crack attraction by the repair (ACAR<span><span><sup>1</sup></span></span>). Here this ACAR test reveals a slight difference in mechanical behavior between the repair and the original coating which motivates further work to eventually make the repair imperceptible.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100284"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133080","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-06-01Epub Date: 2025-01-12DOI: 10.1016/j.jajp.2025.100283
Ning Zhu , Trevor Hickok , Kirk A. Fraser , Dunji Yu , Yan Chen , Ke An , Luke N. Brewer , Paul G. Allison , J. Brian Jordon
This work examines the residual stress in high-strength aluminum alloy repaired by lubricant-free additive friction stir deposition (AFSD) using the same aluminum alloy feedstock. Specifically, a milled groove in an AA7075-T651 substrate was repaired using the twin rod additive friction stir deposition (TR-AFSD) without using any graphite lubricant on the feedstock materials, which is required for conventional square feedstock AFSD. Residual stress distribution in the repaired substrate at different depths was quantified via neutron diffraction, where the distribution of longitudinal residual stress in the TR-AFSD repair was found comparable to materials subjected to other friction-based processes, with an M-shaped or bell-shaped distribution. The tensile longitudinal residual stress, with a peak of 171.3 MPa, spanned the center region around 36 mm, while compressive longitudinal residual stresses, ranging between -112.9 MPa and -12.3 MPa, were balanced outside the center at both the advancing side and retreating sides. The transverse and normal residual stresses were consistent across the repair, with smaller magnitudes between -52 MPa and 68.3 MPa. The non-destructive and high penetration depth nature of the neutron diffraction method enabled the calculation of von Mises stress by interpreting the three measured orthogonal residual stresses as the principal stresses. By normalizing the calculated von Mises stress to the microhardness, this quantified ratio indicates the influence of the embedded residual stresses relative to the material's strength. The higher normalized ratio observed at a deeper depth closer to the bottom of the repair, suggests that the magnitude of residual stresses is closer to the material's strength, indicating a higher potential for residual stress-induced failure at this location. We also calibrated the state-of-the-art smooth particle hydrodynamic (SPH) TR-AFSD process model to predict the von Mises stress distribution in the TR-AFSD AA7075 repair. The experimentally measured residual stress, coupled with the SPH simulation, could further help the research community to minimize the tensile region and alleviate substrate distortion in materials subjected to friction-based processes.
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