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Welding, Joining, and Additive Manufacturing of Metals and Alloys (Second...
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Welding, Joining, and Additive Manufacturing of Metals and Alloys (Second Edition)

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

Deadline for manuscript submissions: 10 May 2025 | Viewed by 2368

Special Issue Editors

Dr. Damjan Klobcar

E-Mail Website
Guest Editor
Faculty of Mechanical Engineering, University of Ljubljana, Aškerčeva 6, 1000 Ljubljana, Slovenia
Interests: additive manufacturing; characterization of weld joints; ultrasonic welding; laser welding; friction stir welding; friction welding; resistance spot welding; arc welding technologies; adhesive bonding
Special Issues, Collections and Topics in MDPI journals
Dr. Drago Bračun

E-Mail Website
Guest Editor
Laboratory for Mechatronics, Production systems and Automation, Faculty of Mechanical Engineering, University of Ljubljana, Ljubljana, Slovenia
Interests: vision systems for industrial quality inspection; deep learning-based image processing; automation; process monitoring and improvement
Dr. Tomaž Vuherer

E-Mail Website
Guest Editor
Laboratory for Welding, Faculty of Mechanical Engineering, University of Maribor, Maribor, Slovenia
Interests: characterisation of weld joints; instrumented charpy test; fatique; fracture mechanics of the weld joints; fatigue crack growth test; friction stir welding; friction welding; resistance spot welding; arc welding technologies; residual stress

Special Issue Information

Dear Colleagues,

The constant development of new materials and products also promotes the research and development of welding, joining, and build-up welding technologies as well as additive manufacturing technologies. These investigations are multidisciplinary and include processes and their automatization, monitoring and control, materials, weldability and joinability of materials and alloys, design of products and joints, and advanced characterisation and numerical simulations to comprehensively understand physical and metallurgical phenomena. A successful understanding of these phenomena enables the development of solutions to overcome these problems. This Special Issue aims to report basic and applied research results as well as case studies in the field of weldability and joinability of materials, additive manufacturing, automation, process improvement, and advanced characterisation.

The potential topics for the Special Issues include, but are not limited to, the following:

  • Micro and nano joining.
  • Diffusion bonding.
  • Adhesive bonding.
  • Hybrid welding and additive manufacturing.
  • Laser welding.
  • Welding with mechanical energy.
  • Weldability of similar and dissimilar materials.
  • Advanced material characterisation.
  • Residual stress and distortion.
  • Numerical modelling and simulation.
  • Additive manufacturing processes (DED, powder bead fusion, binder jetting, etc.).
  • Additive manufacturing of new materials, multi-materials, and functionally graded materials.
  • Improvement in materials using weld surfacing and additive manufacturing.
  • Repair welding and repair additive manufacturing of products.
  • Advanced material characterisation.
  • Fatigue of joints and AM parts.
  • Destructive and non-destructive testing of joints and AM parts.
  • Process automation, monitoring, and control.
  • Vision systems in process monitoring, automation, and quality inspection.

Dr. Damjan Klobcar
Dr. Drago Bračun
Dr. Tomaž Vuherer
Guest Editors

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

  • welding and joining technologies
  • brazing and soldering
  • additive manufacturing
  • advanced material characterization
  • fatigue of joints and AM parts
  • process automation, monitoring, and control
  • vision systems in process monitoring, automation, and quality inspection

 

 

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Related Special Issue

Published Papers (4 papers)

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Research

17 pages, 12866 KiB  
Article
Influence of Ag-18Cu-10Zn Filler Material on Microstructure and Properties of Laser-Welded Al/Cu Dissimilar Butt Joints
by Ziquan He, Fei Liu, Ping Gao, Lihui Pang and Yong Su
Materials 2024, 17(23), 5726; https://doi.org/10.3390/ma17235726 - 22 Nov 2024
Viewed by 315
Abstract
Dissimilar welding between aluminum and copper poses significant challenges, primarily due to differences in their thermal and mechanical properties, resulting in brittle intermetallic compounds, limited joint strength, and high electrical resistivity. This study aims to overcome these issues by employing Ag-18Cu-10Zn filler material [...] Read more.
Dissimilar welding between aluminum and copper poses significant challenges, primarily due to differences in their thermal and mechanical properties, resulting in brittle intermetallic compounds, limited joint strength, and high electrical resistivity. This study aims to overcome these issues by employing Ag-18Cu-10Zn filler material and optimizing laser power with a focus on improving joint strength and electrical conductivity. The results indicate that the incorporation of silver and zinc enhances the phase composition and microstructure of the weld. By forming solid solution phases such as Ag2Al and Cu5Zn8, the brittle Al2Cu phase commonly found in traditional Al/Cu welding is replaced. This not only promotes the heterogeneous nucleation of fine silver-rich grains but also restricts the excessive growth of silver-poor grains, resulting in a uniform distribution of fine grains throughout the weld. These modifications contribute to both fine-grain strengthening and dispersion strengthening. At an optimal laser power of 750 W, joint strength reaches 109 MPa, while joint resistivity decreases to 3.19 μΩ·cm, 12.6% lower than that of the aluminum alloy base material. This study proposes a process for achieving highly conductive, reliable Al/Cu dissimilar metal joints, potentially impacting the aluminum–copper connections in battery modules for new energy vehicles. Full article
(This article belongs to the Special Issue Welding, Joining, and Additive Manufacturing of Metals and Alloys (Second Edition))
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15 pages, 6813 KiB  
Article
Study of the Microstructure and Mechanical Properties of Steel Grades for Ship Hull Construction
by Siavash Imanian Ghazanlou, Ahmad Mobasher Amini, Félix-Antoine Carrier, Dilip K. Sarkar, Kashif Rehman and Mousa Javidani
Materials 2024, 17(23), 5687; https://doi.org/10.3390/ma17235687 - 21 Nov 2024
Viewed by 393
Abstract
This paper comprehensively examines three structural steel grades’ microstructural features and mechanical properties, evaluating their suitability for shipbuilding applications. The steels analyzed include quench and tempered (Q and T) steel, thermomechanical controlled processed (TMCP) steel, and hot rolled (HR) steel. A microstructural characterization [...] Read more.
This paper comprehensively examines three structural steel grades’ microstructural features and mechanical properties, evaluating their suitability for shipbuilding applications. The steels analyzed include quench and tempered (Q and T) steel, thermomechanical controlled processed (TMCP) steel, and hot rolled (HR) steel. A microstructural characterization was performed using optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD). The analysis was complemented by extensive mechanical testing including assessments of hardness, tensile, and Charpy impact tests across a range of temperatures. Additionally, corrosion behavior was evaluated using the potentiodynamic polarization test. The findings revealed that Q and T grade steel exhibited the most refined microstructure, characterized by a complex mixture of ferrite, tempered martensite, upper bainite, and Fe3C phases. In contrast, the TMCP grade steel demonstrated a balanced microstructure of polygonal ferrite and pearlite. Meanwhile, the HR grade steel contained polygonal ferrite and aligned pearlite. The tensile testing results demonstrated that the Q and T grade steel had superior hardness, yield strength (YS), and ultimate tensile strength (UTS), although it exhibited the lowest elongation % (El %). The TMCP grade steel met all ABS standards for marine steels, displaying optimal YS, UTS, and El %. Despite the superior YS of the HR grade steel, it did not meet the necessary criteria for UTS. Charpy impact tests revealed that the TMCP grade steel exhibited the highest impact energy absorption across a range of temperatures. As a result, the TMCP grade steel emerged as the optimal choice for ship construction, fulfilling all ABS requirements with a balanced combination of strength, ductility, and impact energy absorption. Additionally, the potentiodynamic polarization results revealed that the Q and T grade steel demonstrated the highest corrosion resistance. Following Q and T steel, the HR grade steel ranked second in corrosion resistance, with TMCP steel closely behind, showing only a slight difference. Full article
(This article belongs to the Special Issue Welding, Joining, and Additive Manufacturing of Metals and Alloys (Second Edition))
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17 pages, 7468 KiB  
Article
Microstructure and Hardness Properties of Additively Manufactured AISI 316L Welded by Tungsten Inert Gas and Laser Welding Techniques
by Mohamed Elsayed, Mahmoud Khedr, Antti Järvenpää, A. M. Gaafer and Atef Hamada
Materials 2024, 17(18), 4489; https://doi.org/10.3390/ma17184489 - 12 Sep 2024
Viewed by 860
Abstract
In this study, 316L austenitic stainless-steel (ASS) plates fabricated using an additive manufacturing (AM) process were joined using tungsten inert gas (TIG) and laser welding techniques. The 316L ASS plates were manufactured using a laser powder bed fusion (LPBF) technique, with building orientations [...] Read more.
In this study, 316L austenitic stainless-steel (ASS) plates fabricated using an additive manufacturing (AM) process were joined using tungsten inert gas (TIG) and laser welding techniques. The 316L ASS plates were manufactured using a laser powder bed fusion (LPBF) technique, with building orientations (BOs) of 0° and 90°, designated as BO-0 and BO-90, respectively. The study examined the relationship between indentation resistance and microstructure evolution within the fusion zone (FZ) of the welded joints considering the effects of different BOs. Microstructural analysis of the weldments was conducted using optical and laser confocal scanning microscopes, while hardness measurements were obtained using a micro-indentation hardness (HIT) technique via the Berkovich approach. The welded joints produced with the TIG technique exhibited FZs with a greater width than those created by laser welding. The microstructure of the FZs in TIG-welded joints was characterized by dendritic austenite and 1–4 wt.% δ-ferrite phases, while the corresponding microstructure in laser-welded joints consisted of a single austenite phase with cellular structures. Additionally, the grain size values of FZs produced using the laser welding technique were lower than those produced using the TIG technique. Therefore, TIG-welded joints showcased hardness values lower than those welded by laser welding. Furthermore, welded joints with the BO-90 orientation displayed the greatest cooling rates following welding processing, leading to FZs with hardness values greater than BO-0. For instance, the FZs of TIG-welded joints with BO-0 and BO-90 had HIT values of 1.75 ± 0.22 and 2.1 ± 0.09 GPa, whereas the corresponding FZs produced by laser welding had values of 1.9 ± 0.16 and 2.35 ± 0.11 GPa, respectively. The results have practical implications for the design and production of high-performance welded components, providing insights that can be applied to improve the efficiency and quality of additive manufacturing and welding processes. Full article
(This article belongs to the Special Issue Welding, Joining, and Additive Manufacturing of Metals and Alloys (Second Edition))
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18 pages, 16480 KiB  
Article
Effect of Back Plate Preheating Assistance System and Deep Rolling Process on Microstructure Defects and Axial Force Reduction of Friction Stir Welded AA6061 Joint
by Pinmanee Insua, Wasawat Nakkiew, Adirek Baisukhan and Siwasit Pitjamit
Materials 2024, 17(18), 4447; https://doi.org/10.3390/ma17184447 - 10 Sep 2024
Viewed by 570
Abstract
This study investigates the effects of a back plate preheating assistance system and deep rolling (DR) on axial force and tunnel defects during friction stir welding (FSW). Different preheating configurations—advancing side (AS), retreating side (RS), and both sides—were examined to evaluate their impact [...] Read more.
This study investigates the effects of a back plate preheating assistance system and deep rolling (DR) on axial force and tunnel defects during friction stir welding (FSW). Different preheating configurations—advancing side (AS), retreating side (RS), and both sides—were examined to evaluate their impact on axial force reduction, temperature distribution, and defect minimization. Axial force measurements were taken using a dynamometer, and temperature histories were recorded with a thermal camera. The results demonstrate that a preheating temperature of 200 °C is optimal, reducing axial force by 30.24% and enhancing material flow. This temperature also facilitated deeper tool penetration, especially when preheating was applied to both sides. Preheating on the AS resulted in the smallest tunnel defects, reducing defect size by 80.15% on the RS and 96.91% on the AS compared to the non-preheated condition. While DR further reduced tunnel defects, its effectiveness was limited by the proximity of defects to the surface. These findings offer significant insights for improving the FSW process. Full article
(This article belongs to the Special Issue Welding, Joining, and Additive Manufacturing of Metals and Alloys (Second Edition))
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