Journal of Advanced Joining Processes最新文献_第8页

Advances in induction brazing of copper and dissimilar metals: Challenges and emerging trends 铜和异种金属感应钎焊的进展：挑战和新趋势

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-04-04 DOI: 10.1016/j.jajp.2025.100302

Eyuel A. Lemma , João M.S. Dias , António A. Bastos , Bernardo Mascate , Ana Horovistiz

Induction brazing is emerging as a promising technique in current manufacturing processes, particularly noted for its effectiveness in the precise control of heat input, localized heating and rapid processing time. This joining technique is advantageous in industries such as heat pump and refrigeration manufacturing, which require precise and effective joining techniques, particularly for brazing copper and dissimilar metal pipes. Additionally, this technique is environmentally friendly, energy-efficient, cost-effective, and well-suited for automation.

However, studies have shown that induction brazing of copper and dissimilar metals presents several significant challenges, including thermal distortion-induced cracks due to unoptimized heat input and porosity defects stemming from inadequate filler metal penetration and suboptimal gap size between the joint, these issues can compromise joint integrity, as well as system durability and sustainability. Furthermore, the incompatible thermophysical properties of dissimilar materials and interconnectors pose substantial difficulties in achieving complete metallurgical bonding. The formation of undesirable microstructures, such as hard and brittle intermetallic compounds (IMCs), can further affect the structural, mechanical, and thermal properties of brazed joints.

This review systematically examines the effects of the most significant induction brazing process parameters on joint performance. Specifically, the effects of heat input, geometrical gap size between the joints, and composition of the filler material on the quality of brazed joints are discussed. Moreover, this review explores the induction brazing of copper with dissimilar metals, including copper with aluminum and copper with stainless steel. The impact of key process parameters on the joint quality of these materials was analyzed. Additionally, opportunities, challenges, and strategies to mitigate the challenges in induction brazing of copper and dissimilar metals are presented induction brazing are presented along with future research directions.

感应钎焊在当前的制造工艺中是一种很有前途的技术，特别是其在精确控制热输入、局部加热和快速加工时间方面的有效性。这种连接技术在热泵和制冷制造等行业中是有利的，这些行业需要精确和有效的连接技术，特别是钎焊铜和异种金属管道。此外，该技术对环境友好，节能，成本效益高，非常适合自动化。然而，研究表明，铜和异种金属的感应钎焊存在几个重大挑战，包括由于未优化的热输入而导致的热变形引起的裂纹，以及由于填充金属渗透不足和接头之间的间隙尺寸不理想而导致的孔隙缺陷，这些问题可能会损害接头的完整性，以及系统的耐久性和可持续性。此外，不同材料和互连体的不相容的热物理性质给实现完全的冶金结合带来了很大的困难。不良组织的形成，如硬脆的金属间化合物（IMCs），会进一步影响钎焊接头的结构、机械和热性能。本文系统地考察了感应钎焊工艺参数对接头性能的影响。具体地说，讨论了热输入、接头之间的几何间隙大小和填充材料的组成对钎焊接头质量的影响。此外，本文还探讨了铜与不同金属的感应钎焊，包括铜与铝和铜与不锈钢。分析了关键工艺参数对接头质量的影响。此外，提出了铜和异种金属感应钎焊的机遇、挑战和缓解挑战的策略，并提出了感应钎焊的未来研究方向。

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引用次数: 0

Direct bonding mechanism of titanium and PET resin via heating and pressurization: Influence of bubble dynamics on bonding strength 钛与PET树脂加热加压直接结合机理：气泡动力学对结合强度的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-03-28 DOI: 10.1016/j.jajp.2025.100301

Katsuyoshi Kondoh , Nodoka Nishimura , Kazuki Shitara , Shota Kariya , Ke Chen , Junko Umeda

In response to growing environmental concerns, the transportation industry, including automotive and aerospace sectors, has emphasized improving fuel efficiency and reducing carbon dioxide emissions. To achieve significant weight reduction, multi-material design strategies that strategically utilize different materials based on their properties are being adopted. This trend highlights the need for advanced joining technologies capable of bonding dissimilar materials, such as metals and polymers or resins, while maintaining structural integrity and lightweight performance. This study investigates the direct bonding mechanism between pure titanium (Ti) and polyethylene terephthalate (PET) resin using a simple heating and pressurization process. Bubble formation at the bonding interface, a critical factor influencing joint strength, was analyzed through in-situ observation. Results show that controlled bubble dynamics enhance bonding by creating localized pressure, while excessive bubbles act as defects. Optimal bonding conditions were identified at 200–300 °C with relatively high bonding shear stress. X-ray photoelectron spectroscopy revealed the formation of Ti-C bonds, confirming strong chemical interactions at the interface. Additionally, pyrolysis gas chromatography-mass spectrometry identified ethylene glycol as a key component in bubble generation during thermal decomposition of PET. The findings highlight the significance of surface preparation, thermal control, and bubble management in achieving high bonding strength. This research provides insights into sustainable and efficient methods of dissimilar materials that can improve recyclability and support the development of advanced lightweight structures.

为了应对日益增长的环境问题，包括汽车和航空航天部门在内的交通运输业强调提高燃油效率和减少二氧化碳排放。为了实现显著的重量减轻，采用多材料设计策略，根据其特性战略性地利用不同的材料。这一趋势凸显了对先进连接技术的需求，这种技术能够连接不同的材料，如金属、聚合物或树脂，同时保持结构完整性和轻量化性能。本研究采用简单的加热加压工艺研究了纯钛（Ti）与聚对苯二甲酸乙二醇酯（PET）树脂之间的直接键合机理。通过现场观察，分析了影响接头强度的关键因素——界面气泡的形成。结果表明，可控的气泡动力学通过产生局部压力来增强粘接，而过多的气泡则会形成缺陷。在200 ~ 300℃，较高的剪切应力条件下，确定了最佳的粘结条件。x射线光电子能谱揭示了Ti-C键的形成，证实了界面上强烈的化学相互作用。此外，热解气相色谱-质谱分析发现乙二醇是PET热分解过程中产生气泡的关键成分。研究结果强调了表面制备、热控制和气泡管理对实现高结合强度的重要性。这项研究为不同材料的可持续和高效方法提供了见解，这些方法可以提高可回收性，并支持先进轻质结构的发展。

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引用次数: 0

Fatigue crack growth and residual stress in simultaneous double-sided friction stir welded aluminum alloy AA6061-T6 双面搅拌摩擦焊接铝合金AA6061-T6的疲劳裂纹扩展及残余应力

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-03-26 DOI: 10.1016/j.jajp.2025.100300

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

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.

搅拌摩擦焊作为一种固态焊接方法，在包括AA6061-T6在内的铝合金中表现出了显著的有效性，并广泛应用于汽车和航空航天工程领域。然而，传统的FSW方法通常会导致残余应力分布不均匀，从而影响材料的抗疲劳开裂能力。同时双面搅拌摩擦焊（SDFSW）的引入克服了这一限制，通过从两侧焊接来提高焊接质量。研究了刀具转速对AA6061-T6铝合金SDFSW过程中疲劳裂纹扩展和残余应力分布的影响。采用几种转速组合来评估其对接头质量的影响，包括残余应力分布和循环载荷性能。基于先前的实验，SDFSW工艺使用了上、下刀具速度。这些是965/965 rpm， 967/1251 rpm和965/1555 rpm。疲劳裂纹扩展试验按照ASTM E647标准进行，残余应力分布采用x射线衍射cos α法进行评估。进行了额外的机械性能评估，包括射线照相分析、宏观组织和微观组织检查、显微硬度测试、抗拉强度评估和断裂表征。研究结果表明，刀具的转速显著影响焊缝区显微组织，影响力学性能、残余应力分布和裂纹扩展行为。在测试条件下，工具转速为965/1555 rpm时，最高抗拉强度约为179.82 MPa，约为母材强度的53%，最高显微硬度为85 HV。这种速度组合也表现出较低的疲劳裂纹扩展速率，Paris定律系数C和n分别为2E-08和3.6931，并且残余应力分布更有利。

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引用次数: 0

Application of stress-state-dependent ductile damage and failure model to clinch joining for a wide range of tool and material combinations 应力状态相关的延性损伤和失效模型在各种工具和材料组合的夹持连接中的应用

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-03-24 DOI: 10.1016/j.jajp.2025.100299

Johannes Friedlein , Stephan Lüder , Jan Kalich , Hans Christian Schmale , Max Böhnke , Malte Schlichter , Mathias Bobbert , Gerson Meschut , Paul Steinmann , Julia Mergheim

The clinch joining process is simulated for 22 different tool- and material-combinations, using a modular axisymmetric finite element simulation model. Two ductile metals are considered for the sheets, namely the dual-phase steel HCT590X and the aluminium alloy EN AW-6014 T4. A finite elasto-plastic material model is utilised to capture the inherent large plastic strains. Moreover, it is coupled to stress-state-dependent ductile damage and failure to successfully predict possible fracture during the clinch joining process. For all 22 clinch combinations a good agreement is obtained between simulations and experiments, regarding the geometry of the clinch joint, the process force and the occurrence of material failure. This represents a significant advance in the development and comprehension of a versatile process chain resulting from joint research efforts. The validated process simulations are then applied to study the influence of the tool geometries, sheet pre-stretch, and friction. Failure is herein always observed by neck fracture. Nevertheless, detailed analyses of the stress state evolution during the joining process for various locations reveal that the material is exposed to distinctly non-proportional loading paths demanding suitable stress-state-dependent evolution laws. Moreover, even for valid joints, process-induced damage is distributed throughout the joint. Incorporating the damage-induced softening causes an accelerated failure evolution, but has less influence on the global behaviour.

采用模块化轴对称有限元仿真模型，模拟了22种不同的刀具和材料组合的夹紧连接过程。考虑了两种韧性金属，即双相钢HCT590X和铝合金EN AW-6014 T4。有限弹塑性材料模型用于捕获固有的大塑性应变。此外，它还与应力状态相关的延性损伤和无法成功预测夹接过程中可能发生的断裂相关联。对于所有22种夹紧组合，在夹紧接头的几何形状、工艺力和材料失效的发生方面，模拟结果与实验结果吻合较好。这代表了在开发和理解由联合研究努力产生的通用过程链方面的重大进步。然后应用验证的过程模拟来研究刀具几何形状、板材预拉伸和摩擦的影响。在这里，失败通常以颈部骨折来观察。然而，对不同位置连接过程中应力状态演化的详细分析表明，材料暴露于明显的非比例加载路径，需要合适的应力状态相关演化规律。此外，即使是有效的关节，过程损伤也分布在整个关节中。考虑损伤引起的软化会加速破坏演变，但对整体行为的影响较小。

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引用次数: 0

Hot corrosion mechanism in transient liquid phase bonded HX superalloy: Effect of bonding time 瞬态液相结合HX高温合金的热腐蚀机理：结合时间的影响

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-02-28 DOI: 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.

本研究研究了在900°C的Na2SO4-V2O5熔盐环境下，哈氏合金X （HX）的瞬态液相（TLP）键合的热腐蚀行为，测试了不同的键合时间（5、20、80、320和640分钟）。在1070℃下进行粘接，观察腐蚀产物及显微组织特征。显微组织分析证实了接头中存在初生共晶相，包括富ni硼化物和硅化物、Ni-Si共晶和几种富铬硼化物。粘结时间为20和80 min的样品耐热腐蚀性能较差。相反，由于合金元素分布更均匀，界面处的硼化物浓度更低，结合320分钟的样品表现出更好的电阻。热腐蚀试验初期，TLP表面覆盖一层致密的Cr2O3和NiO涂层。热腐蚀20 h后，由于氧化层与钒发生反应，形成NaVO3，而硫的扩散导致内部以Ni、Cr、Mo为主的硫化物的演化。NaVO3和SO3的存在以及Cr2O3的还原，显著影响了长时间暴露后的耐热腐蚀性能。

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引用次数: 0

Aluminum surface treatment and process optimization: Boosting mechanical performance in aluminum/polypropylene composite friction stir lap joints 铝表面处理及工艺优化：提高铝/聚丙烯复合搅拌摩擦搭接接头的力学性能

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-02-26 DOI: 10.1016/j.jajp.2025.100297

Mojtaba Movahedi, Mahtab Mohsenirad, Ashkaan Ozlati

The effects of chemical surface treatment of aluminum sheet and tool rotational speed (in the range of 300–1100 rpm) were studied on the macro/microstructure and mechanical behavior of friction stir lap joints between aluminum-magnesium aluminum alloy and a polypropylene composite containing 20 wt.% talc and 10 wt.% elastomer. Macrostructural studies of the joints revealed the formation of macroscopic mechanical locks between the aluminum and polymer base sheets, characterized by aluminum pieces resembling anchors penetrating the polymer substrate. The size of the anchors decreased as the rotational speed increased, and their orientation changed from being parallel with the interface of the aluminum/composite sheets to being perpendicular, and then facing the opposite direction. The larger anchors, as well as those penetrating relatively perpendicular into the polymer composite substrate, provided the joints with the highest fracture load and absorbed energy up to peak load at the intermediate tool rotational speeds of 700 and 900 rpm. Microstructural analysis demonstrated that chemical surface treatment with a solution of HCl and FeCl₃ in distilled water significantly increased the surface roughness of the aluminum sheet (by a factor of ∼4) and created numerous microscopic voids on its surface. The molten polymer formed during welding penetrated into these voids, creating numerous microscopic mechanical locks. These locks substantially enhanced the tensile-shear performance of the joints, resulting in up to ∼80 % higher fracture load and ∼380 % higher absorbed energy compared to joints without surface treatment of the aluminum. The influence of the morphology of mechanical locks on the location and mode of joint fracture was also investigated.

研究了铝板表面化学处理和刀具转速（300 ~ 1100转/分）对铝镁铝合金与含20 wt.%滑石粉和10 wt.%弹性体的聚丙烯复合材料搅拌摩擦接件宏观组织和力学行为的影响。对接头的宏观结构研究表明，铝基片与聚合物基片之间形成了宏观机械锁，其特征是铝片类似锚点穿透聚合物基片。随着转速的增加，锚固体尺寸减小，锚固体的取向由与铝/复合材料界面平行变为垂直，再朝向相反方向。较大的锚，以及相对垂直穿透聚合物复合基板的锚，在700和900 rpm的中间工具转速下，为接头提供了最高的断裂载荷，并吸收了高达峰值载荷的能量。显微结构分析表明，用蒸馏水中的HCl和FeCl3溶液进行化学表面处理显著提高了铝板的表面粗糙度（约4倍），并在其表面产生了许多微观空洞。在焊接过程中形成的熔融聚合物渗透到这些空隙中，形成了许多微观的机械锁。这些锁大大提高了接头的抗拉剪切性能，与未进行铝表面处理的接头相比，断裂载荷提高了~ 80%，吸收能量提高了~ 380%。研究了机械锁的形态对关节断裂的位置和方式的影响。

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引用次数: 0

Feasibility study of advanced manufacturing processes: Integrating LPBF and LMD for Inconel 718 先进制造工艺的可行性研究：针对铬镍铁合金 718 整合 LPBF 和 LMD

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-02-19 DOI: 10.1016/j.jajp.2025.100296

Pinku Yadav , Olivier Rigo , Corinne Arvieu , Eric Lacoste

Laser hybrid manufacturing combines Laser Powder Bed Fusion (LPBF) and Laser Melt Deposition (LMD) to overcome LPBF's size constraints and LMD's lower geometric precision. This study explores the feasibility of hybrid LPBF-LMD processing for Inconel 718, focusing on interface properties and mechanical performance. Hybrid samples were first fabricated using LPBF, followed by LMD, with LMD process parameters optimized using a second-order parabolic model. Two LPBF variants as-built and solution-annealed were evaluated to assess their influence on interface characteristics. Microstructural analysis revealed a fine-grained LPBF region and a coarser LMD region with distinct texture, both demonstrating defect-free metallurgical bonding. Microhardness measurements showed a gradient at the LPBF interface, increasing from 346 ± 20 HV at the build plate to 410 ± 18 HV, influenced by solidification and thermal gradients. The LMD region exhibited a lower hardness of 314 ± 12 HV, correlating with its coarser microstructure. Tensile tests showed that as-built LPBF-LMD samples had higher elongation (26.76 ± 2 %) compared to solution-annealed samples (8.29 ± 2 %), with the LPBF region contributing more to ductility. These findings provide key insights into optimizing hybrid LPBF-LMD processing for high-performance components, enabling improved repair strategies and multifunctional part design in aerospace, energy, and other critical applications.

激光混合制造将激光粉末床熔合（LPBF）和激光熔体沉积（LMD）相结合，克服了LPBF的尺寸限制和LMD较低的几何精度。本研究从界面性能和力学性能两方面探讨了混合LPBF-LMD加工Inconel 718的可行性。混合样品首先采用LPBF制备，然后采用LMD制备，LMD工艺参数采用二阶抛物模型优化。对构建的两种LPBF变体和溶液退火进行了评估，以评估它们对界面特性的影响。显微组织分析显示，细粒LPBF区和较粗的LMD区具有明显的织构，均显示无缺陷的冶金结合。显微硬度测量结果显示，受凝固梯度和热梯度的影响，LPBF界面处存在梯度，从构建板处的346±20 HV增加到410±18 HV。LMD区的硬度较低，为314±12 HV，显微组织较粗。拉伸试验表明，LPBF- lmd试样的伸长率（26.76±2%）高于固溶退火试样（8.29±2%），且LPBF区域对延性的贡献更大。这些发现为优化高性能部件的混合LPBF-LMD加工提供了关键见解，从而改善了航空航天、能源和其他关键应用中的维修策略和多功能部件设计。

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引用次数: 0

Comparative analysis of structural and mechanical properties of duplex stainless steel (DSS) weldments prepared by flux core arc welding and shielded metal arch welding processes 双相不锈钢（DSS）焊条药芯电弧焊与保护金属拱焊结构与力学性能的对比分析

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-02-18 DOI: 10.1016/j.jajp.2025.100295

E. Ajenifuja , A.P.I. Popoola , O. Popoola

Duplex stainless steel (DSS) possesses wide range of useful metallographic and mechanical properties; hence the material has been used in different forms of application namely in chloride present environments such as desalination plants and cooling water services such as conventional and nuclear power stations. However, this material has its limitations as it's susceptible to cracking particularly stress corrosion cracking or pitting corrosion and can exhibit poor metallurgical properties such as microstructures and phase containing unbalanced proportions of ferrite and austenite. In this study, Flux Core Arc Welding (FCAW) is compared with Shielded Metal Arch Welding (SMAW) process, in terms of their effects on the structural and mechanical properties and performances of DSS weldments. Analysis of the microstructure and phases were carried out. Also, the tensile, microhardness, impact and fracture properties were determined with relevant techniques. The results indicated that SMAW and FCAW welding processes differentially influence the structural and mechanical properties of the DSS weldments, consisting of the part of base material, weld and the heat affected zone (HAZ). The weld prepared using the SMAW process exhibited superior hardness characteristics at 309 HV and achieved the highest impact energy absorption of 145.92 J. In contrast, the FCAW prepared weldment exhibited the highest tensile strength, reaching 282.30 kN maximum load.

双相不锈钢（DSS）具有广泛的实用金相和力学性能；因此，该材料已被用于不同形式的应用，即在氯化物存在的环境中，如海水淡化厂和冷却水服务，如常规和核电站。然而，这种材料有其局限性，因为它容易开裂，特别是应力腐蚀开裂或点蚀，并且可能表现出较差的冶金性能，例如微观结构和含铁素体和奥氏体比例不平衡的相。在本研究中，比较了药芯电弧焊（FCAW）与保护金属弧焊（SMAW）工艺对DSS焊接件的结构、力学性能和性能的影响。进行了显微组织和物相分析。用相关技术测定了材料的拉伸性能、显微硬度、冲击性能和断裂性能。结果表明，SMAW和FCAW焊接工艺对DSS焊件的组织性能和力学性能有不同的影响，包括母材部分、焊缝和热影响区。采用SMAW工艺制备的焊缝在309 HV时具有优异的硬度特性，达到了145.92 j的最大冲击吸能，而采用FCAW工艺制备的焊件具有最高的抗拉强度，达到了282.30 kN的最大载荷。

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引用次数: 0

Correlating geometry, microstructure and properties of High Strength Steel thin wall structures fabricated with WAAM WAAM制备高强钢薄壁结构的几何、微观结构和性能研究

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-02-15 DOI: 10.1016/j.jajp.2025.100292

Aravind Babu, Emiliano Trodini, José Luis Galán Argumedo, Ian M. Richardson, Marcel J.M. Hermans

Wire arc additive manufacturing (WAAM) of high-strength steel (HSS) has gained significant attention for structural applications. Achieving precise control over the manufacturing process and understanding the relationship between process parameters and the resulting material characteristics is crucial for optimizing the performance of these steel walls to achieve tailored properties. The present study was performed to comprehend the influence of process parameters on the microstructure and properties of wire arc additively manufactured (WAAM) high-strength steel (HSS) thin-wall structures. Multi-layer thin walls of ER110S-G high-strength steel comprising 30 layers were deposited bidirectionally and were fabricated with different travel speeds and wire-feed rates. Geometrical analysis conducted on samples indicates that achieving minimal surface waviness for single-bead thin walls depends on adjusting wire feed rates and travel speeds. Specifically, lower wire feed rates are found to be more effective in minimizing waviness when dealing with single-bead thin walls (thickness

<

5 mm). Conversely, lower travel speeds are preferred for reducing surface irregularities in walls fabricated at high deposition rates for thicker single-bead walls (thickness

>

8 mm). Cooling rate analysis from midpoints of the 5th, 15th and 25th layers of each sample indicates high cooling rates for low heat input (HI=178 J/mm) samples even for the

25 th

layer. Microstructural characterization of the samples suggests an increase in acicular ferrite and martensite volume fraction with lower heat input. Additionally, microstructural quantification with EBSD reveals smaller grain sizes and higher Kernel average misorientation for low heat input deposits. Mechanical properties like hardness and tensile strength display an increasing trend with decreasing heat input while elongation to fracture is reduced under the same conditions. Furthermore, anisotropic behaviour is observed in tensile strength and elongation to fracture between building and deposition directions due to the presence of microstructural inhomogeneities.

高强度钢（HSS）的电弧增材制造（WAAM）在结构应用中得到了广泛的关注。实现对制造过程的精确控制，了解工艺参数与最终材料特性之间的关系，对于优化这些钢壁的性能以实现定制性能至关重要。研究了工艺参数对电弧增材制造（WAAM）高强度钢（HSS）薄壁结构组织和性能的影响。采用双向沉积法制备了30层ER110S-G高强度钢薄壁，并在不同的行程速度和送丝速度下进行了制备。对样品进行的几何分析表明，要实现单头薄壁的最小表面波纹取决于调整送丝速度和行进速度。具体来说，当处理单头薄壁(厚度<；5毫米)。相反，对于较厚的单壁(厚度>；8毫米)。从每个样品的第5层、第15层和第25层的中点进行冷却速率分析表明，即使在第25层，低热输入（HI=178 J/mm）样品的冷却速率也很高。显微组织表征表明，在较低的热输入下，针状铁素体和马氏体体积分数增加。此外，利用EBSD进行的显微组织定量分析表明，低热输入沉积层的晶粒尺寸更小，内核平均取向偏差更高。硬度、抗拉强度等力学性能随热输入的减小而增大，而断裂伸长率随热输入的减小而减小。此外，由于微观结构不均匀性的存在，在建筑和沉积方向之间的抗拉强度和断裂伸长率表现出各向异性。

{"title":"Correlating geometry, microstructure and properties of High Strength Steel thin wall structures fabricated with WAAM","authors":"Aravind Babu, Emiliano Trodini, José Luis Galán Argumedo, Ian M. Richardson, Marcel J.M. Hermans","doi":"10.1016/j.jajp.2025.100292","DOIUrl":"10.1016/j.jajp.2025.100292","url":null,"abstract":"<div><div>Wire arc additive manufacturing (WAAM) of high-strength steel (HSS) has gained significant attention for structural applications. Achieving precise control over the manufacturing process and understanding the relationship between process parameters and the resulting material characteristics is crucial for optimizing the performance of these steel walls to achieve tailored properties. The present study was performed to comprehend the influence of process parameters on the microstructure and properties of wire arc additively manufactured (WAAM) high-strength steel (HSS) thin-wall structures. Multi-layer thin walls of ER110S-G high-strength steel comprising 30 layers were deposited bidirectionally and were fabricated with different travel speeds and wire-feed rates. Geometrical analysis conducted on samples indicates that achieving minimal surface waviness for single-bead thin walls depends on adjusting wire feed rates and travel speeds. Specifically, lower wire feed rates are found to be more effective in minimizing waviness when dealing with single-bead thin walls (thickness <span><math><mo><</mo></math></span> 5 mm). Conversely, lower travel speeds are preferred for reducing surface irregularities in walls fabricated at high deposition rates for thicker single-bead walls (thickness <span><math><mo>></mo></math></span> 8 mm). Cooling rate analysis from midpoints of the 5th, 15th and 25th layers of each sample indicates high cooling rates for low heat input (HI=178 J/mm) samples even for the <span><math><mrow><mn>25</mn><mi>th</mi></mrow></math></span> layer. Microstructural characterization of the samples suggests an increase in acicular ferrite and martensite volume fraction with lower heat input. Additionally, microstructural quantification with EBSD reveals smaller grain sizes and higher Kernel average misorientation for low heat input deposits. Mechanical properties like hardness and tensile strength display an increasing trend with decreasing heat input while elongation to fracture is reduced under the same conditions. Furthermore, anisotropic behaviour is observed in tensile strength and elongation to fracture between building and deposition directions due to the presence of microstructural inhomogeneities.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100292"},"PeriodicalIF":3.8,"publicationDate":"2025-02-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143464927","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}

引用次数: 0

Mechanical properties and microstructure of the C70600 copper-nickel alloy and C46500 brass joint using brazing technique C70600铜镍合金与C46500黄铜钎焊接头的力学性能和显微组织

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes

Pub Date : 2025-02-11 DOI: 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.

海军黄铜（C46500），由于在这种合金中存在锡，它具有很高的抗大气和水腐蚀性能。这种类型的黄铜广泛应用于各种行业，包括船舶应用，电气元件等。C70600铜镍合金由于形成固溶体，在提高抗拉强度的同时保持了较高的延展性。高耐海水腐蚀，归因于大量的锰和铁，是该合金的关键特性之一。在船舶应用中需要这些合金的连接。考虑到固溶体和金属间化合物的形成及其对机械性能的影响，控制它们的数量对于获得最佳结果至关重要。钎焊被认为是连接这些基材的有效方法。由于温度和时间是钎焊过程中影响析出相形成的两个关键参数，因此本研究的重点是优化这两个参数，以获得理想的显微组织和力学性能。钎焊过程在16种不同的条件下进行，包括650、680、710和740°C，持续1、5、15和30分钟。采用光学显微镜、扫描电镜（SEM）、x射线能谱仪（EDS）和x射线衍射仪（XRD）研究了接头的微观结构和接头区域的相关相变。通过强度测试和显微硬度测试来评估样品的力学性能。结果表明：随着连接温度的升高和连接时间的延长，由于扩散速率的增加，热凝固区宽度减小，而等温凝固区宽度增大；此外，延长钎焊时间会促进相偏析。当试样在710°C下连接15 min时，强度达到106.4 MPa，断口呈现韧性-脆性混合模式。

{"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":"2025-02-11","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}

引用次数: 0