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Advances in the Experimentation and Numerical Modeling of Material Joining Processes (Second Edition)

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Materials Simulation and Design".

Deadline for manuscript submissions: 20 April 2025 | Viewed by 7874

Special Issue Editor

Dr. Raul D. S. G. Campilho

E-Mail Website
Guest Editor
Departamento de Engenharia Mecânica, Instituto Superior de Engenharia do Porto, 4200-072 Porto, Portugal
Interests: advanced manufacturing systems; automation and robotics; industrial design
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Nowadays, structural design is facing major challenges in the associated joining processes, such as material selection, different thermal coefficients and melting points, multi-material joining, the joining of thin-walled structures, traditional process effectiveness for new materials, cost efficiency and ecological issues. To provide a strong, reliable and lightweight solution for a given application, the designer should either consider hybrid joining or choose from a large variety of available processes, such as welding, brazing, riveting, mechanical fastening, adhesive bonding, clinching, friction stir welding, laser welding, diffusion welding, amongst others. These joining processes have evolved towards optimization and cost reduction in the early design stages in terms of their implementation and industrialization, destructive and non-destructive testing, and either analytical or numerical modeling. Numerical modeling is particularly effective for simulating complex geometries, different load scenarios and materials with plasticity or anisotropy. The finite element method, together with fracture mechanics techniques, is a powerful and common approach employed in the scientific community, but less applied for the study of complex loads, such as high strain rates, fatigue or impact, and it is seldom used in the industry. To develop state-of-the-art techniques and disseminate the recent advances in all types of joining, either experimental or numerical, this Special Issue intends to bring together a significant number of high-quality contributions to this field of research through innovative and original works, subsequently promoting their dissemination via open access publishing.

Dr. Raul D. S. G. Campilho
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • joining process
  • welding
  • brazing
  • riveting
  • mechanical fastening
  • adhesive bonding
  • clinching
  • friction stir welding
  • laser welding
  • diffusion welding
  • hybrid joining
  • experimental testing
  • numerical modeling
  • strength prediction
  • failure path prediction
  • finite element method
  • fracture mechanics
  • static load
  • dynamic load
  • impact load
  • fatigue load
  • residual stress
  • mechanical properties
  • thin-walled structures

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Related Special Issue

Published Papers (6 papers)

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Research

13 pages, 3019 KiB  
Article
Effect of Post-Cured through Thickness Reinforcement on Disbonding Behavior in Skin–Stringer Configuration
by Jimesh D. Bhagatji, Christopher Morris, Yogaraja Sridhar, Bodhisatwa Bhattacharjee, Krishnanand N. Kaipa and Oleksandr G. Kravchenko
Materials 2024, 17(14), 3389; https://doi.org/10.3390/ma17143389 - 9 Jul 2024
Cited by 1 | Viewed by 804
Abstract
An experimental investigation of interlaminar toughness for post-cured through-thickness reinforcement (PTTR) skin–stringer sub-element is presented. The improvement in the crack resistance capability of skin–stringer samples was shown through experimental testing and finite element analysis (FEA) modeling. The performance of PTTR was evaluated on [...] Read more.
An experimental investigation of interlaminar toughness for post-cured through-thickness reinforcement (PTTR) skin–stringer sub-element is presented. The improvement in the crack resistance capability of skin–stringer samples was shown through experimental testing and finite element analysis (FEA) modeling. The performance of PTTR was evaluated on a pristine and initial-disbond of the skin–stringer specimen. A macro-scale pin–spring modeling approach was employed in FEA using a non-linear spring to capture the pin failure under the mixed-mode load. The experimental results showed a 15.5% and 20.9% increase in strength for the pristine-PTTR and initial-disbond PTTR specimens, respectively. The modeling approach accurately represents the overall structural response of PTTR laminate, including stiffness, adhesive strength, crack extension scenarios and progressive pin failure modes. This modeling approach can be beneficial for designing damage-tolerant structures by exploring various PTTR arrangements for achieving improved structural responses. Full article
(This article belongs to the Special Issue Advances in the Experimentation and Numerical Modeling of Material Joining Processes (Second Edition))
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12 pages, 26650 KiB  
Article
Mechanical and Physicochemical Characteristics of a Novel Premixed Calcium Silicate Sealer
by Naji Kharouf, Filippo Cardinali, Raya Al-Rayesse, Ammar Eid, Ziad Moujaes, Mathilda Nafash, Hamdi Jmal, Frédéric Addiego and Youssef Haikel
Materials 2024, 17(13), 3374; https://doi.org/10.3390/ma17133374 - 8 Jul 2024
Viewed by 1006
Abstract
The aim of the present in vitro study was to evaluate specific mechanical and physicochemical properties of three calcium silicate-based sealers, BioRoot™ Flow (BRF), CeraSeal (CRS) and TotalFill® (TF). Samples were prepared to evaluate different physicochemical and mechanical properties of the tested [...] Read more.
The aim of the present in vitro study was to evaluate specific mechanical and physicochemical properties of three calcium silicate-based sealers, BioRoot™ Flow (BRF), CeraSeal (CRS) and TotalFill® (TF). Samples were prepared to evaluate different physicochemical and mechanical properties of the tested sealers. These evaluations were accomplished by investigating the pH changes over time, porosity, roughness, flow properties, compressive strength and wettability. The results were statistically evaluated using one-way analysis of variance. All three sealers demonstrated an alkaline pH from 1 h of immersion in water to 168 h. A higher porosity and hydrophily were detected in BRF samples compared to CRS and TF. No significant difference was found between the tested materials in the flow properties. Lower compressive strength values were observed for BRF compared to TF and CRS. Differently shaped structures were detected on the three materials after 7 days of immersion in PBS. The three materials demonstrated a higher solubility than 3% after 24 h of immersion in water (CRS < BRF < TF). The novel premixed calcium silicate sealer (BRF) had comparable physicochemical properties to the existing sealers. The lower compressive strength values could facilitate the removal of these materials during retreatment procedures. Further studies should investigate the biological effects of the novel sealer. Full article
(This article belongs to the Special Issue Advances in the Experimentation and Numerical Modeling of Material Joining Processes (Second Edition))
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19 pages, 11127 KiB  
Article
Fatigue Strength Assessment of Friction Welds under Consideration of Residual Stress
by Lorenz Uhlenberg, Jörg Baumgartner, Christoph Rößler, David Schmicker, Markus Köhler, Frank Trommer and Klaus Dilger
Materials 2024, 17(13), 3130; https://doi.org/10.3390/ma17133130 - 26 Jun 2024
Viewed by 1079
Abstract
A reliable local-fatigue assessment approach for rotary friction-welded components does not yet exist. The scope of this paper is to present test results for the fatigue behaviour of rotary friction-welded solid shafts made of structural steel S355J2G3 (1.0570) and an approach to fatigue [...] Read more.
A reliable local-fatigue assessment approach for rotary friction-welded components does not yet exist. The scope of this paper is to present test results for the fatigue behaviour of rotary friction-welded solid shafts made of structural steel S355J2G3 (1.0570) and an approach to fatigue assessment considering residual stress. In contrast to fusion-welded joints, components made by rotary friction welding usually contain compressive residual stress near the weld, which can significantly affect the fatigue strength. For this purpose, specimens were welded and characterised, including metallographic micrographs, hardness measurements, and residual stress measurements. The fatigue tests were performed with a constant amplitude loading in tension/compression or torsion with R = −1. All specimens were investigated without machining of the weld flash, either in the as-welded state or after a post-weld stress-relief heat treatment. In addition, the friction welding process and the residual stress formation were analysed using numerical simulation. The characterisation results are integrated into a fatigue assessment approach. Overall, the specimens perform comparatively well in the fatigue tests and the experimentally observed fatigue behaviour is well described using the proposed local approaches. Full article
(This article belongs to the Special Issue Advances in the Experimentation and Numerical Modeling of Material Joining Processes (Second Edition))
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15 pages, 4692 KiB  
Article
Kinetic Study of Anaerobic Adhesive Curing on Copper and Iron Base Substrates
by Juana Abenojar, Sara López de Armentia, Juan Carlos del Real and Miguel Angel Martínez
Materials 2024, 17(12), 2886; https://doi.org/10.3390/ma17122886 - 13 Jun 2024
Viewed by 746
Abstract
Anaerobic adhesives (AAs) cure at room temperature in oxygen-deprived spaces between metal substrates. The curing process is significantly influenced by the type of metal ions present. This study investigates the curing kinetics of a high-strength AA on iron and copper substrates using differential [...] Read more.
Anaerobic adhesives (AAs) cure at room temperature in oxygen-deprived spaces between metal substrates. The curing process is significantly influenced by the type of metal ions present. This study investigates the curing kinetics of a high-strength AA on iron and copper substrates using differential scanning calorimetry (DSC). The activation energy and kinetic parameters were determined with different empiric models, revealing that curing on copper is faster and more complete compared to iron. The findings suggest that copper ions lower the activation energy required for curing, enhancing the adhesive’s performance. This research addresses the gap in understanding how metal ions affect AA curing kinetics, offering valuable insights for optimizing adhesive formulations for industrial applications. Full article
(This article belongs to the Special Issue Advances in the Experimentation and Numerical Modeling of Material Joining Processes (Second Edition))
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16 pages, 9350 KiB  
Article
Simulation of Mechanical Stresses in BaTiO3 Multilayer Ceramic Capacitors during Desoldering in the Rework of Electronic Assemblies Using a Framework of Computational Fluid Dynamics and Thermomechanical Models
by Adam Yuile, Erik Wiss, David Barth and Steffen Wiese
Materials 2024, 17(11), 2702; https://doi.org/10.3390/ma17112702 - 3 Jun 2024
Cited by 1 | Viewed by 674
Abstract
Multilayer ceramic capacitors (MLCCs) are critical components when thermal processes such as reflow desoldering are used during rework of electronic assemblies. The capacitor’s ferroelectric BaTiO3 body is very brittle. Therefore, thermomechanical stresses can cause crack formation and create conductive paths that may [...] Read more.
Multilayer ceramic capacitors (MLCCs) are critical components when thermal processes such as reflow desoldering are used during rework of electronic assemblies. The capacitor’s ferroelectric BaTiO3 body is very brittle. Therefore, thermomechanical stresses can cause crack formation and create conductive paths that may short the capacitor. In order to assess the thermally induced mechanical stresses onto an MLCC during reflow desoldering, simulations were carried out, which make use of a framework of computational fluid dynamics and thermomechanical models within the ANSYS software package. In the first step, CFD simulations were conducted to calculate the transient temperature field in the surrounding of the MLCC component, which was then used as an input for FEM simulations to compute the arising mechanical stresses inside the MLCC. The results of the simulations show that the major contribution to mechanical stresses within the MLCC component comes from the mismatch in thermal expansion between the printed circuit board and the MLCC. The temperature gradients along the MLCC component are rather small and account only for moderate internal stresses within the brittle BaTiO3 body. Full article
(This article belongs to the Special Issue Advances in the Experimentation and Numerical Modeling of Material Joining Processes (Second Edition))
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22 pages, 6228 KiB  
Article
Thermal–Mechanical and Microstructural Simulation of Rotary Friction Welding Processes by Using Finite Element Method
by Hossein Mani, Aboozar Taherizadeh, Behzad Sadeghian, Behzad Sadeghi and Pasquale Cavaliere
Materials 2024, 17(4), 815; https://doi.org/10.3390/ma17040815 - 8 Feb 2024
Cited by 2 | Viewed by 1516
Abstract
Rotary friction welding is one of the most crucial techniques for joining different parts in advanced industries. Experimentally measuring the history of thermomechanical and microstructural parameters of this process can be a significant challenge and incurs high costs. To address these challenges, the [...] Read more.
Rotary friction welding is one of the most crucial techniques for joining different parts in advanced industries. Experimentally measuring the history of thermomechanical and microstructural parameters of this process can be a significant challenge and incurs high costs. To address these challenges, the finite element method was used to simulate thermomechanical and microstructural aspects of the welding of identical superalloy Inconel 718 tubes. Numerical simulation results were used to compute essential mechanical and metallurgical parameters such as temperature, strain, strain rate, volume fraction of dynamic recrystallization, and grain size distribution. These parameters were subsequently verified using experimental test results. The Johnson–Avrami model was utilized in the microstructural simulation to convert thermomechanical parameters into metallurgical factors, employing a FORTRAN subroutine. The calculated thickness of the recrystallization zone in the wall was 480 and 850 μm at the tube wall’s center and edge, respectively. These values were reported from experimental measurements as 500 and 800 μm, respectively. The predicted grain size changes from the center to the edge of the wall thickness, near the weld interface, ranged from 2.07 to 2.15 μm, comparable to the experimental measurements ranging from 1.9 to 2.2 μm. Various curves are also presented to explore the correlation between thermomechanical and microstructural parameters, with the experimental results revealing predictable microstructure evolutions correlated with thermomechanical changes. Full article
(This article belongs to the Special Issue Advances in the Experimentation and Numerical Modeling of Material Joining Processes (Second Edition))
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