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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Advanced Composites".

Deadline for manuscript submissions: closed (10 September 2024) | Viewed by 23145

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Dr. Cheng Gu

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Guest Editor

College of Materials Science and Engineering, Chongqing University, Chongqing, China
Interests: welding; microstructure; solidification; Al alloy; simulation; cellular automaton
Special Issues, Collections and Topics in MDPI journals

Dr. Gaoyang Mi

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Guest Editor

College of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan, China
Interests: welding; microstructure; solidification; Al alloy; aluminum matrix composites
Special Issues, Collections and Topics in MDPI journals

Dr. Wenmin Ou

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Guest Editor

School of Automotive Engineering, Changshu Institute of Technology, Changshu, China
Interests: wire arc additive manufacturing; material process simulation; friction stir welding of dissimilar aluminum alloy

Special Issue Information

Dear Colleagues,

Welding is a promising way to fabricate multi-material structures to achieve weight reduction and high functionalization. However, no welding method can be applied or used universally for different materials, such as aluminum alloys, copper alloys, steel, etc. With the development of new materials such as metal matrix composites and high entropy alloys, different welding methods have been developed and used in addition to conventional fusion welding, e.g., friction stir welding, ultrasonic spot welding, laser–arc hybrid welding, diffusion welding, and so on. It is difficult to obtain high-strength and defect-free welding joints for materials with various physical properties. Research has concentrated on the welding characteristics of different alloys and composites, and the acquisition of high-strength welding joints will be the most important criterion for their wider application. The goal of this Special Issue is to describe recent developments in this developing research field. Therefore, we invite you to submit manuscripts to this Special Issue. Full papers, communications, and reviews are all welcome.

Dr. Cheng Gu
Dr. Gaoyang Mi
Dr. Wenmin Ou
Guest Editors

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Keywords

welding
alloy
composites
solidification
molten pool
metallurgical bonding
microstructure
fluid flow
welding joints

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Advances in Welding of Alloy and Composites (2nd Edition) in Materials

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Research

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15 pages, 4486 KiB

Open AccessArticle

Simulation of Friction Stir Welding of AZ31 Mg Alloys

by Sili Feng, Zhe Liu and Renlong Xin

Materials 2024, 17(20), 4974; https://doi.org/10.3390/ma17204974 - 11 Oct 2024

Viewed by 645

Abstract

Friction stir welding has been extensively applied for the high-quality bonding of Mg alloys. The welding temperature caused by friction and plastic deformation is essential for determining the joint characteristics, especially the residual stress and weld microstructure. In this work, a modified moving heat source model was proposed by considering the variations in heat generation caused by friction shear stress at both the side and bottom surfaces of the tool. The application of this model was further extended to the entire welding process, especially in the plunging stage. The relative errors between the experimental and simulated peak temperatures at characteristic points were small, with a maximum of 10%, thereby validating the model for accurate temperature prediction. Furthermore, the influence of welding and rotational speed on temperature fields was systematically investigated. At relatively low welding and rotational speeds, the welding temperature increased significantly with either an increase in rotational speed or a decrease in welding speed. However, this effect gradually diminished at higher welding and rotational speeds. These results provide some valuable guidelines for controlling heat generation to improve the quality of Mg alloy welds. Full article

(This article belongs to the Special Issue Advances in Welding of Alloy and Composites)

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16 pages, 19093 KiB

Open AccessArticle

Microstructure and Mechanical Properties of Mg-Li/Al Dissimilar Joints via Dynamic Support Friction Stir Lap Welding

by Yisong Gao, Yingying Zuo, Huijie Liu, Dongrui Li and Xuanmo Li

Materials 2024, 17(12), 2883; https://doi.org/10.3390/ma17122883 - 13 Jun 2024

Viewed by 662

Abstract

In this study, two-mm-thick dual-phase LA103Z Mg-Li and 6061 Al alloys, known for their application in lightweight structural designs, were joined using dynamic support friction stir lap welding (DSFSLW). The microstructural evolution and mechanical properties of dissimilar joints were investigated at different welding speeds. The analysis revealed two distinct interfaces: the diffusion interface and the mixed interface. The diffusion interface, characterized by a pronounced diffusion zone, is formed under slower welding speeds. The diffusion zone height, the effective lap width, and the interface layer thickness decrease with increasing welding speed due to low plastic deformation capacity and weak interfacial reactions. Conversely, the mixed interface, associated with higher welding speeds, contained large Al fragments. The extremely high microhardness values (130.5 HV) can be ascribed to the formation of intermetallic compounds (IMCs) and strain-hardened Al fragments. Notably, the maximum shear strength achieved was 175 N/mm at a welding speed of 20 mm/min. The fracture behavior varied significantly with the interface type; the diffusion interface showed enhanced mechanical strength due to better intermetallic reactions and interlocking structures, while the mixed interface displayed more linear crack propagation due to weaker IMCs and the absence of hook structures. Fracture surface analysis indicates that fractures are more likely to propagate through the Al matrix and interface layers. Full article

(This article belongs to the Special Issue Advances in Welding of Alloy and Composites)

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13 pages, 12284 KiB

Open AccessArticle

Effects of Cu/SnAgCu Powder Fraction and Sintering Time on Microstructure and Mechanical Properties of Transient Liquid Phase Sintered Joints

by Dinh-Phuc Tran, Yu-Ting Liu and Chih Chen

Materials 2024, 17(9), 2004; https://doi.org/10.3390/ma17092004 - 25 Apr 2024

Cited by 1 | Viewed by 743

Abstract

The effects of the sintering duration and powder fraction (Ag-coated Cu/SnAgCu) on the microstructure and reliability of transient liquid phase sintered (TLPS) joints are investigated. The results show that two main intermetallic compounds (IMCs, Cu₆Sn₅ and Cu₃Sn) formed in the joints. The Cu₆Sn₅ ratio generally decreased with increasing sintering time, Cu powder fraction, and thermal treatment. The void ratio of the high-Cu-fraction joints decreased and increased with increasing sintering and thermal stressing durations, respectively, whereas the low-Cu-fraction counterparts were stable. We also found that the shear strength increased with increasing thermal treatment time, which resulted from the transformation of Cu₆Sn₅ and Cu₃Sn. Such findings could provide valuable information for optimizing the TLPS process and assuring the high reliability of electronic devices. Full article

(This article belongs to the Special Issue Advances in Welding of Alloy and Composites)

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18 pages, 9063 KiB

Open AccessArticle

The Development of a Continuous Constitutive Model for Thin-Shell Components with A Sharp Change in the Property at Welded Joints

by Zhubin He, Xianggang Ruan, Jiangkai Liang, Jian Ning, Yanli Lin and Kelin Chen

Materials 2024, 17(8), 1796; https://doi.org/10.3390/ma17081796 - 13 Apr 2024

Viewed by 1138

Abstract

Large-dimension complex integral thin-shell components are widely used in advanced transportation equipment. However, with the dimensional limitations of raw blanks and the manufacturing process, there are inhomogeneous geometric and mechanical properties at welded joints after welding, which have a significant effect on the subsequent forming process. Therefore, in this paper, the microstructure of welded joints with a sharp property change was accurately characterized by the proposed isothermal treatment method using the BR1500HS welded tube as an example. In addition, an accurate constitutive model of welded tubes was established to predict the deformation behavior. Firstly, the heat-treated specimens were subjected to uniaxial tensile tests and the stress–strain curves under different heat treatment conditions were obtained. Then, the continuous change in flow stress in the direction of the base metal zone, the heat-affected zone and the weld zone was described by the relationship between the microhardness, flow stress and center angle of the welded tube. Using such a method, a continuous constitutive model of welded tubes has been established. Finally, the constitutive model was compiled into finite-element software as a user material subroutine (VUHARD). The reliability of the established constitutive model was verified by simulating the free hydro-bulging process of welded tubes. The results indicated that the continuous constitutive model can well describe the deformation response during the free hydro-bulging process, and accurately predicted the equivalent strain distribution and thickness thinning rate. This study provides guidance in accurately predicting the plastic deformation behavior of welded tubes and its application in practice in hydroforming industries. Full article

(This article belongs to the Special Issue Advances in Welding of Alloy and Composites)

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21 pages, 10568 KiB

Open AccessArticle

Microstructures and Corrosion/Localised Corrosion of Stainless Steels, Incoloy and Their Weldments in Nitrite-Containing Chloride Environments

by R. K. Singh Raman and W. H. Siew

Materials 2024, 17(6), 1336; https://doi.org/10.3390/ma17061336 - 14 Mar 2024

Viewed by 864

Abstract

Prompted by the unexpected observation of the pitting of the weldments of a highly corrosion- and pitting-resistant duplex stainless steel, SAF2507, in chloride solutions with nitride addition, the pitting and corrosion resistance of SAF2507 and its weldments were investigated in chloride solutions with and without different levels of nitrite. The Incoloy 825 and 316L austenitic stainless steels were included for the purpose of developing a comparative appreciation. The microstructures of the weldments were characterised, and 316L showed a profound influence of nitrite addition in inhibiting pitting, while ‘meta-stable’ pitting transients that were clearly visible in the chloride solution without nitrite were absent when nitrite was added. Both the parent metal and the weldment of SAF2507 had similar pitting potential (E_p) in 0.1 M NaCl without nitrite, which was the highest E_p among the three alloys tested. Additions of nitrite at low concentrations had an inhibitive effect on pitting, whereas higher nitrite contents had a deleterious effect on pitting resistance. On the other hand, Incoloy 825 showed a trend of E_p ennoblement with an increasing nitrite content of 0.1 M NaCl, and the weldment underwent greater ennoblement. Moreover, 316L showed a trend similar to Incoloy 825; however, the E_p ennoblements were significantly more pronounced for both the weldment and the base metal of 316L. Full article

(This article belongs to the Special Issue Advances in Welding of Alloy and Composites)

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14 pages, 11757 KiB

Open AccessArticle

The Effect of Fe Content on the Microstructure and Tensile Properties of Friction-Stir-Welded Joints in Recycled Cast Aluminum Alloy

by Fujian Gong, Gang Feng, Yajun Wang, Sha Lan, Jinsheng Zhang, Chun Wang, Jianhua Zhao, Qing Yang and Zhibai Wang

Materials 2024, 17(1), 64; https://doi.org/10.3390/ma17010064 - 22 Dec 2023

Cited by 1 | Viewed by 1181

Abstract

The presence of the impurity element Fe significantly influences the overall performance of recycled aluminum alloy. This study aims to elucidate the impact of Fe content on the microstructure and tensile properties of friction-stir-welded (FSW) joints in recycled cast A356 aluminum alloy. Three samples with varying Fe content were prepared for FSW joints. The quality of the weld zone was meticulously assessed through macrostructure and microstructure analyses. The tensile strengths of the joints were carefully evaluated and correlated with the microhardness and microstructure of the weld zone. The research findings reveal that, among the three fabricated joints, the one with an Fe content of 0.3 wt.% demonstrates the most favorable tensile performance. This particular joint exhibits the highest tensile strength of 153 MPa, commendable yield strength of 90 MPa, and a favorable elongation of 5.7%. The mechanisms responsible for grain refinement in the weld nugget zone involve plastic deformation and dynamic recrystallization. Significantly, the disruptive effects of friction-stir action on eutectic silicon phases and rich iron phases emerge as crucial factors contributing to the enhanced performance of the weld nugget zone in the welded joint. Full article

(This article belongs to the Special Issue Advances in Welding of Alloy and Composites)

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12 pages, 6716 KiB

Open AccessArticle

Molecular Dynamic Simulation and Experiment Validation on the Diffusion Behavior of Diffusion Welded Fe-Ti by Hot Isostatic Pressing Process

by Cheng Gu, Sheng Zeng, Weili Peng, Guoqiang You, Jianhua Zhao and Yajun Wang

Materials 2023, 16(16), 5626; https://doi.org/10.3390/ma16165626 - 15 Aug 2023

Cited by 2 | Viewed by 1272

Abstract

A reliable bonding interface between steel and Ti alloy is required for producing a steel/Ti bimetal composite. In this study, molecular dynamic simulations and diffusion welding experiments using the hot isostatic pressing process were conducted to study the atomic diffusion at the Fe-Ti interface. The simulation results indicate that the diffusion layer thickness is thinner in single crystals compared to polycrystals at the same temperature. This difference may be explained by polycrystals having grain boundaries, which increase atomic disorder and facilitate diffusion. The radial distribution function (RDF) curves for Fe-Fe and Ti-Ti exhibit a similar pattern over time, with a main peak indicating the highest atom density within a specific radius range and relatively strong binding between the central atoms and their nearest neighbors. The observed changes in the diffusion coefficient with temperature in the simulations align well with the experimental results. This study enhances the understanding of Fe-Ti interface diffusion mechanism and provides valuable insights for broader applications of steel/Ti bimetal composites. Full article

(This article belongs to the Special Issue Advances in Welding of Alloy and Composites)

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15 pages, 12313 KiB

Open AccessArticle

Solidification and Liquation Cracking in Welds of High Entropy CoCrFeNiCu_x Alloys

by Ping Yu, Sindo Kou and Chun-Ming Lin

Materials 2023, 16(16), 5621; https://doi.org/10.3390/ma16165621 - 14 Aug 2023

Cited by 1 | Viewed by 1501

Abstract

High entropy CoCrFeNiCu_x alloys with a Cu molar ratio of x ≈ 0, 0.5, 1, 1.5 and 2 were arc welded. Solidification cracking occurred in the fusion zones of alloys with x ≈ 0.5, 1 and 1.5. Cu-rich material was observed around cracks, increasing in quantity with increasing Cu content. Liquation cracking occurred in the partially melted zone next to the fusion zone, and it propagated into the fusion zone as solidification cracking. A recently proposed index for the susceptibility to solidification cracking was tried, i.e., |dT/d(f_S)^1/2| near (f_S)^1/2 = 1, where T is temperature and f_S the solid fraction. The index was higher in alloys with x ≈ 0.5, 1.0 and 1.5, consistent with the solidification cracking observed. Full article

(This article belongs to the Special Issue Advances in Welding of Alloy and Composites)

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23 pages, 11371 KiB

Open AccessArticle

Microstructural Evolution and Mechanical Performance of Two Joints of Medium-Mn Stainless Steel with Low- and High-Alloyed Steels

by Mahmoud Khedr, I. Reda Ibrahim, Matias Jaskari, Mohammed Ali, Hamed A. Abdel-Aleem, Tamer S. Mahmoud and Atef Hamada

Materials 2023, 16(4), 1624; https://doi.org/10.3390/ma16041624 - 15 Feb 2023

Cited by 8 | Viewed by 2008

Abstract

In this work, 2 mm thick medium-Mn austenitic stainless steel (MMn–SS) plates were joined with austenitic NiCr stainless steel (NiCr–SS) and low-carbon steel (LCS) using the gas tungsten arc welding technique. A precise adjustment of the welding process parameters was conducted to achieve high-quality dissimilar joints of MMn–SS with NiCr–SS and LCS. The microstructural evolution was studied using laser scanning confocal and electron microscopes. Secondary electron imaging and electron backscatter diffraction (EBSD) techniques were intensively employed to analyze the fine features of the weld structures. The mechanical properties of the joints were evaluated by uniaxial tensile tests and micro-indentation hardness (H_IT). The microstructure of the fusion zone (FZ) in the MMn–SS joints exhibited an austenitic matrix with a small fraction of δ-ferrite, ~6%. The tensile strength (TS) of the MMn–SS/NiCr–SS joint is significantly higher than that of the MMn–SS/LCS joint. For instance, the TSs of MMn–SS joints with NiCr–SS and LCS are 610 and 340 MPa, respectively. The tensile properties of MMn–SS/LCS joints are similar to those of BM LCS, since the deformation behavior and shape of the tensile flow curve for that joint are comparable with the flow curve of LCS. The H_IT measurements show that the MMn–SS/NiCr–SS joint is significantly stronger than the MMn–SS/LCS joint since the H_IT values are 2.18 and 1.85 GPa, respectively. Full article

(This article belongs to the Special Issue Advances in Welding of Alloy and Composites)

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Review

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73 pages, 32288 KiB

Open AccessReview

A Review on Friction Stir Welding/Processing: Numerical Modeling

by Mostafa Akbari, Parviz Asadi and Tomasz Sadowski

Materials 2023, 16(17), 5890; https://doi.org/10.3390/ma16175890 - 28 Aug 2023

Cited by 28 | Viewed by 11844

Abstract

Friction stir welding (FSW) is a manufacturing process that many industries have adopted to join metals in a solid state, resulting in unique properties. However, studying aspects like temperature distribution, stress distribution, and material flow experimentally is challenging due to severe plastic deformation in the weld zone. Therefore, numerical methods are utilized to investigate these parameters and gain a better understanding of the FSW process. Numerical models are employed to simulate material flow, temperature distribution, and stress state during welding. This allows for the identification of potential defect-prone zones. This paper presents a comprehensive review of research activities and advancements in numerical analysis techniques specifically designed for friction stir welding, with a focus on their applicability to component manufacturing. The paper begins by examining various types of numerical methods and modeling techniques used in FSW analysis, including finite element analysis, computational fluid dynamics, and other simulation approaches. The advantages and limitations of each method are discussed, providing insights into their suitability for FSW simulations. Furthermore, the paper delves into the crucial variables that play a significant role in the numerical modeling of the FSW process. Full article

(This article belongs to the Special Issue Advances in Welding of Alloy and Composites)

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