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Recent Advances in Materials Welding and Joining Technologies

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A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Materials Science and Engineering".

Deadline for manuscript submissions: closed (20 November 2024) | Viewed by 8848

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Special Issue Editors

Dr. Lubos Kascak

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Department of Technology, Materials and Computer Supported Production, Faculty of Mechanical Engineering, Technical University of Košice, 04002 Košice, Slovakia
Interests: mechanical joining; clinching; resistance spot welding; adhesive bonding; hybrid joining; metal additive process; machining
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Prof. Dr. Emil Spišák

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Guest Editor

Department of Technologies, Materials and Computer Aided Production, Technical University of Kosice, 74 Mäsiarska, 04001 Kosice, Slovakia
Interests: sheet metal forming; mechanical joining; modeling and simulation of technological processes
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Dr. Jacek Mucha

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Guest Editor

Faculty of Mechanical Engineering and Aeronautics, Rzeszów University of Technology, 35-959 Rzeszów, Poland
Interests: construction and operation of machines; technologies for the production of mechanical joints; analysis of the mechanical properties of joints; operation of plastic forming tools
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

At present, the material concepts used for various products vary considerably, but the common goal is the economic efficiency of production while maintaining customer requirements. Since complex products can consist of different types of ferrous and non-ferrous metals or the now increasingly used composite materials, the question arises not only of how to manufacture the parts of the assembly but also how to combine them into a functional whole and maintain the required quality. Therefore, research in the area of joining materials of different grades, thicknesses, or combinations is very important. The main goal in the field of joining technologies is to develop and offer a comprehensive solution for joining new materials with various mechanical properties and chemical compositions to improve the economy of the production process.

This Special Issue includes original research and review studies regarding the aspects of joining technologies for various types of materials: ferrous and non-ferrous metals, composites, hybrid materials, and other modern materials. The Speical Issue will provide a platform for presenting the latest scientific knowledge in the field of joining materials using various methods based on welding, mechanical joining, and combinations of various joining methods. The research should be focused on joining materials with an emphasis on the evaluation of the properties of the joints (static and dynamic strength properties, corrosion resistance, etc.) or the prediction of the properties of the joints using the means of numerical simulations. The latest information on trends in the applications of joining systems for joining new materials with different physical and chemical properties will be expected.

Dr. Lubos Kascak
Prof. Dr. Emil Spišák
Dr. Jacek Mucha
Guest Editors

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Keywords

welding
mechanical joining
combination of joining methods
hybrid joining
FEM analysis

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Published Papers (5 papers)

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Research

17 pages, 11583 KiB

Open AccessArticle

The Influence of Low-Pressure Plasma Treatments on the Lap Shear Strength of Laser-Joined AISI 304 Hybrids with Polypropylene and Polyamide 6.6

by Wolfgang Tillmann, Lukas Wojarski, Christian Hopmann, Patricia Fatherazi and Christian Timmer

Appl. Sci. 2023, 13(24), 13275; https://doi.org/10.3390/app132413275 - 15 Dec 2023

Viewed by 943

Abstract

This paper investigates if the polar groups induced by a plasma treatment can increase the lap shear strength of laser-joined metal and plastic hybrids. Optimal laser joining parameters for cold-rolled AISI304–polyamide 6.6 and sandblasted AISI304–polypropylene hybrids were developed at 2.85 MPa and 4.22 MPa, respectively. The surface free energy was doubled for all used plasma gases to a value of ca. 80 mN m⁻¹ at 180 s. The plasma-treated samples were joined and tested. The arithmetic means of the plasma-treated hybrids’ lap shear strength with polyamide 6.6 varied slightly, but all measured values were within the range of the untreated samples. Residue on the sheared metal samples indicated covalent bonds between AISI304 and polyamide 6.6. The lap shear strengths of the plasma-treated polypropylene hybrids were significantly reduced between −30.8% and −53.3%, depending on the used plasma gas. This was attributed to the over-aging and development of low-molecular-weight oxidized materials, which led to a weak boundary layer. No residue of polypropylene was found on treated or untreated lap shear samples. No correlation between the surface free energy and lap shear strength could be found. Full article

(This article belongs to the Special Issue Recent Advances in Materials Welding and Joining Technologies)

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13 pages, 1943 KiB

Open AccessArticle

Failure Analysis of Resistance Spot-Welded Structure Using XFEM: Lifetime Assessment

by Murat Demiral and Ertugrul Tolga Duran

Appl. Sci. 2023, 13(19), 10923; https://doi.org/10.3390/app131910923 - 2 Oct 2023

Cited by 3 | Viewed by 1806

Abstract

Due to their effective and affordable joining capabilities, resistance spot-welded (RSW) structures are widely used in many industries, including the automotive, aerospace, and manufacturing sectors. Because spot-welded structures are frequently subjected to cyclic stress conditions while in service, fatigue failure is a serious concern. It is essential to comprehend and predict their fatigue behavior in order to guarantee the dependability and durability of the relevant engineering products. The analysis of fatigue failure in spot-welded structures is the main topic of this paper, along with the prediction of fatigue life (N_f) and identification of failure mechanisms. Also, the effects of parameters such as the amount of cyclic load applied, the load ratio, and size of the spot-welding on the N_f were investigated. To achieve this, the fatigue performance of spot-welded joints was simulated using the extended finite element method (XFEM). The XFEM method is particularly suited for capturing intricate crack patterns in spot-welded structures because it allows for the modeling of crack propagation without the need for remeshing. It was observed that when the cycling load was decreased by 20%, N_f increased by around 250%. On the other hand, the fatigue life of the structure, and, hence, the crack propagation rate, was significantly affected by the load ratio and diameter of the spot-welding. This paper presents the details of the novel approach to studying spot-weld fatigue characterization using XFEMs to simulate crack propagation. Full article

(This article belongs to the Special Issue Recent Advances in Materials Welding and Joining Technologies)

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19 pages, 5453 KiB

Open AccessArticle

Precision and Dimensional Stability of Bonded Joints of Carbon-Fibre-Reinforced Polymers Parts

by Radim Kupčák, Jan Zouhar, Jindřich Viliš, Lukáš Gregor and Denisa Hrušecká

Appl. Sci. 2023, 13(18), 10413; https://doi.org/10.3390/app131810413 - 18 Sep 2023

Viewed by 1127

Abstract

This article aims to investigate the accuracy and dimensional stability of bonded metal and CFRP (Carbon Fibre Reinforced Plastic) adherends. The motivation behind this study was to assess the suitability of CFRP for optical devices through the evaluation of precision bonding technology. A binocular was selected as a reference optical device. A technological sample was designed, with required total runout of key dimensions 0.05 mm. The sample underwent testing according to ISO 9022-1. The total runout was evaluated after production and environmental tests. Eight out of 15 samples were turned after gluing due to insufficient accuracy. None of the turned samples exceeded the total runout deviation of 0.01 mm, and the average value of the maximal deviation was 0.0041 mm. The noncalibrated samples performed significantly worse with the average value of the maximal deviation of 0.0164 mm. The measurements during the climatic tests showed that the largest deviation (on average 77.6% of the maximum achieved deviation) occurs at the first temperature loading. Subsequent temperature cycles caused lower deviations. The results highlight the significance of addressing deformations resulting from adhesive volume shrinkage-induced stress as a crucial factor in precision bonding technology. Full article

(This article belongs to the Special Issue Recent Advances in Materials Welding and Joining Technologies)

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25 pages, 39721 KiB

Open AccessArticle

Clinching of High-Strength Steel Sheets with Local Preheating

by Miroslav Džupon, Ľuboš Kaščák, Denis Cmorej, Lucia Čiripová, Jacek Mucha and Emil Spišák

Appl. Sci. 2023, 13(13), 7790; https://doi.org/10.3390/app13137790 - 1 Jul 2023

Cited by 7 | Viewed by 2078

Abstract

Clinching is a manufacturing method of mechanically joining two or more materials without the use of heat or additional components. This process relies on high plastic deformation to create a secure bond. Clinching technology is widely used for joining materials of various grades and thicknesses. Especially in the automotive industry, clinching is an alternative to resistance spot welding. However, the load-bearing capacity of clinched joints is comparatively lower when compared to resistance spot-welded joints. This research aimed to increase the load-carrying capacity of clinched joints. To enhance the load-bearing capacity of the clinched joints, localized modification of the microstructure was carried out, primarily focusing on the neck area of the joint. The alteration of the microstructure within the clinched joint was accomplished through the application of localized heating using the resistance spot welding method. The microstructure distribution in the clinched joint region was analyzed using light and scanning electron microscopy, as well as microhardness measurements. Two material grades, micro-alloyed steel HX420LAD+Z and dual-phase ferritic–martensitic steel HCT600X+Z, were tested. Each grade underwent five groups of ten samples, which were subjected to identical experimental conditions of local heating by resistance spot welding (RSW) and clinching. The utilization of RSW on the clinched joint region resulted in an average enhancement of 17% in the load-carrying capacity for material HCT600X+Z, and an average increase of 25% for material HX420LAD+Z. Full article

(This article belongs to the Special Issue Recent Advances in Materials Welding and Joining Technologies)

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23 pages, 7064 KiB

Open AccessArticle

Investigating the Welding Parameters in Friction Stir Welding of Yellow Brass 405-20

by Syed Farhan Raza, Muhammad Amjad, Muhammad Salman Habib, Naveed Ahmed and Fahid Riaz

Appl. Sci. 2023, 13(4), 2433; https://doi.org/10.3390/app13042433 - 14 Feb 2023

Cited by 2 | Viewed by 1886

Abstract

This research presents the numerical and empirical efforts to investigate the effect of friction stir welding (FSW) parameters on the weld temperature, weld strength, and weld hardness for novel brass known as yellow brass 405-20. The numerical approaches used to measure the weld temperature and weld strength were studied for the first time for yellow brass 405-20 and their validations via empirical studies. Two numerical models were simulated including transient thermal analysis and static structural analysis. Thermal distribution leading to maximum weld temperature during FSW of yellow brass was investigated via both simulations and experiments. Moreover, the ultimate tensile strength, namely the weld strength, was measured numerically and validated from its empirical counterpart. Finally, weld hardness was measured empirically to explore the joint health. A maximum temperature of 598 °C was recorded, which was much below the melting point of brass. Joint strength of 228 MPa was observed, which is 83% of the base brass strength. Microscopic examination of the weldment revealed the underlying mechanisms of less weld strength as compared to the parent brass material strength. Full article

(This article belongs to the Special Issue Recent Advances in Materials Welding and Joining Technologies)

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