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Advances in Welding and Mechanical Joining of Metals
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Advances in Welding and Mechanical Joining of Metals

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Welding and Joining".

Deadline for manuscript submissions: closed (20 June 2024) | Viewed by 9901

Special Issue Editor

Dr. Pasquale Russo Spena

E-Mail Website
Guest Editor
Department of Management and Production Engineering, Politecnico di Torino, 10129 Torino, Italy
Interests: friction stir welding; friction stir spot welding; laser welding; arc welding; resistance spot welding; mechanical joining; monitoring of welding processes; friction stir additive manufacturing; mechanical and microstructural characterization; welding simulation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The latest advancements in welding and mechanical joining have enhanced the performance and integrity of assembled components and joining together dissimilar materials that cannot be addressed with conventional methods (e.g., aluminum/steel; steel/composites).

This Special Issue aims at collecting contributions about recent advances in welding and mechanical joining used to assemble, under similar and dissimilar configurations, metals and nonmetals in several industrial fields (e.g., the automotive, aeronautics, aerospace, and energy industries) through high-quality manuscripts. Review articles are also of interest.

Contributions can include but are not limited to:

  • New welding and mechanical joining technologies;
  • Solid-state welding processes, including friction stir welding, friction stir spot welding, explosive welding, ultrasonic welding, and other innovative solid-state innovative technologies;
  • Fusion welding processes, including laser welding, electron beam welding, resistance welding, capacitor discharge welding,  and other innovative fusion welding technologies;
  • Mechanical joining, including self-piercing riveting, clinching, friction element welding,  and other innovative mechanical joining technologies;
  • Hybrid welding and mechanical joining processes, including arc-laser welding, resistance element welding, resistance rivet welding, self-penetrating resistance element welding, arc spot welding, and other innovative hybrid welding and mechanical joining technologies;
  • Process optimization of advanced welding and mechanical joining processes;
  • Monitoring and control of advanced welding and mechanical joining processes;
  • Numerical simulation of advanced welding and mechanical joining processes;
  • Development of innovative tools and equipment;
  • Mechanical and microstructural characterizations of the assembled parts and joints.

Dr. Pasquale Russo Spena
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. Metals is an international peer-reviewed open access monthly 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

  • fusion welding
  • solid-state welding
  • mechanical joining
  • hybrid welding
  • joint quality
  • welding and mechanical joining optimization
  • metals and nonmetals
  • modeling and FEM simulation
  • welding tools and equipment
  • microstructure–mechanical property relationships

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  • Greater discoverability: Special Issues support the reach and impact of scientific research. Articles in Special Issues are more discoverable and cited more frequently.
  • Expansion of research network: Special Issues facilitate connections among authors, fostering scientific collaborations.
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Further information on MDPI's Special Issue polices can be found here.

Published Papers (6 papers)

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Research

15 pages, 16997 KiB  
Article
Active and Passive Filling Stir Repairing of AISI 304 Alloy
by Vincenzo Lunetto, Dario Basile, Valentino Razza and Pasquale Russo Spena
Metals 2024, 14(8), 911; https://doi.org/10.3390/met14080911 - 11 Aug 2024
Viewed by 1298
Abstract
This study investigates active filling friction stir repair (AF-FSR) and passive filling friction stir repair (PF-FSR) for repairing AISI 304 stainless steel sheets, focusing on addressing the challenges posed by high melting point metals. The research involved repairing overlapping 2 mm thick sheets [...] Read more.
This study investigates active filling friction stir repair (AF-FSR) and passive filling friction stir repair (PF-FSR) for repairing AISI 304 stainless steel sheets, focusing on addressing the challenges posed by high melting point metals. The research involved repairing overlapping 2 mm thick sheets with pre-drilled holes of 2, 4, and 6 mm diameters, simulating broken components. Various process parameters, including rotational speed, dwell time, and the use of metal fillers, were tested to evaluate their impact on repair quality. The results demonstrated that PF-FSR provided superior mechanical strength to AF-FSR, particularly for larger pre-hole diameters. PF-FSR achieved higher shear tension strength due to better defect filling and reduced void formation, with shear tension strengths exceeding 25 kN for larger pre-holes and lower variability in strength measurements. AF-FSR was less effective for larger pre-holes, resulting in significant voids and reduced strength. Microstructural analysis revealed that PF-FSR facilitated more efficient material mixing and filling, minimizing unrepaired regions. However, excessive rotational speeds and dwell times in PF-FSR led to deformation and flash formation, highlighting the need for optimal parameter selection. Although further studies are needed, this study confirms the feasibility of FSR techniques for repairing small defects in AISI 304 steels, offering valuable insights for sustainable manufacturing practices in industries such as automotive and aerospace, where efficient and reliable repair methods are critical. Full article
(This article belongs to the Special Issue Advances in Welding and Mechanical Joining of Metals)
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12 pages, 6446 KiB  
Article
An Investigation into the Microstructures and Mechanical Properties of a TIG Welding Joint in Ti-4Al-2V Titanium Alloy
by Yao Chen, Xiao Liu, Zhendi Zhang, Kaiqing Wang, Shanglin Zhang, Bingnan Qian, Jun Wu and Li Wang
Metals 2024, 14(5), 596; https://doi.org/10.3390/met14050596 - 19 May 2024
Viewed by 930
Abstract
The Ti-4Al-2V (wt. %) titanium alloy has garnered widespread applications across diverse fields due to its exceptional strength-to-weight ratio, high toughness, specific strength, and corrosion resistance. The welding of Ti-4Al-2V titanium alloy components is often necessary in manufacturing processes, where the reliability of [...] Read more.
The Ti-4Al-2V (wt. %) titanium alloy has garnered widespread applications across diverse fields due to its exceptional strength-to-weight ratio, high toughness, specific strength, and corrosion resistance. The welding of Ti-4Al-2V titanium alloy components is often necessary in manufacturing processes, where the reliability of a welded joint critically influences the overall service life of these components. Consequently, a comprehensive understanding of the welded joint’s microstructure and mechanical properties is imperative. In this study, Ti-4Al-2V titanium alloy was welded using multi-layer and multi-pass TIG welding techniques, and a detailed examination was conducted to analyze the microstructure and grain morphology of each microzone of the welded joint. The results revealed the presence of an initial α phase and a secondary lamellar α phase in the heat affected zone (HAZ). Meanwhile, the fusion zone (FZ) primarily comprised a coarse secondary α phase and a small amount of an acicular martensitic α’ phase. Both the recrystallization zone and the superheated zone exhibited a distinct preferred orientation, with grains smaller than 10 μm accounting for 65.9% and 55.1%, respectively. To assess the mechanical properties of the various microzones and the typical microstructure within the welded joint, nanoindentation tests were performed. The results indicated that the recrystallization zone possessed a higher nanohardness (3.753 GPa) than the incomplete recrystallization zone (3.563 GPa) and the superheated zone (3.48 GPa). Among all the microzones, the FZ exhibited the lowest average nanohardness (3.058 GPa). Notably, the basket-weave microstructure demonstrated the highest average nanohardness, reaching 3.93 GPa. This was followed by the fine-grain microstructure, which possessed a slightly lower nanohardness. The Widmanstätten microstructure, on the other hand, exhibited the lowest nanohardness among the three microstructures within the HAZ. Therefore, the basket-weave microstructure stands out as the most desirable microstructure to achieve in the welded joint. In summary, this study provides a comprehensive characterization and analysis of the microstructure and properties of Ti-4Al-2V titanium alloy TIG welds, aiming to contribute to the optimization of the TIG welding process for Ti-4Al-2V titanium alloy. Full article
(This article belongs to the Special Issue Advances in Welding and Mechanical Joining of Metals)
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24 pages, 8863 KiB  
Article
Exploring Resistance Spot Welding for Grade 2 Titanium Alloy: Experimental Investigation and Artificial Neural Network Modeling
by Marwan T. Mezher, Diego Carou and Alejandro Pereira
Metals 2024, 14(3), 308; https://doi.org/10.3390/met14030308 - 6 Mar 2024
Cited by 4 | Viewed by 1595
Abstract
The resistance spot welding (RSW) process is still widely used to weld panels and bodies, particularly in the automotive, railroad, and aerospace industries. The purpose of this research is to examine how RSW factors such as welding current, welding pressure, welding time, holding [...] Read more.
The resistance spot welding (RSW) process is still widely used to weld panels and bodies, particularly in the automotive, railroad, and aerospace industries. The purpose of this research is to examine how RSW factors such as welding current, welding pressure, welding time, holding time, squeezing time, and pulse welding affect the shear force, micro-hardness, and failure mode of spot welded titanium sheets (grade 2). Resistance spot welded joints of titanium sheets with similar and dissimilar thicknesses of 1–1 mm, 0.5–0.5 mm, and 1–0.5 mm were evaluated. The experimental conditions were arranged using the design of experiments (DOE). Moreover, artificial neural network (ANN) models were used. Different training and transfer functions were tested using the feed-forward backpropagation approach to find the optimal ANN model. According to the experimental results, the maximum shear force was 5.106, 4.234, and 4.421 kN for the 1–1, 0.5–0.5, and 1–0.5 mm cases, respectively. The hardness measurements showed noticeable improvement for the welded joints compared to the base metal. The findings revealed that the 0.5–0.5 mm case gives the highest nugget and heat-affected zone (HAZ) hardness compared to other cases. Moreover, different failure modes like pull-out nugget, interfacial, and partial failure between the pull-out nugget and interfacial failure were noticed. The ANN outcomes based on the mean squared error (MSE) and coefficient of determination (R2) as validation metrics demonstrated that using the Levenberg–Marquardt (Trainlm) training function with the log sigmoid transfer function (Logsig) gives the best prediction, where R2 and MSE values were 0.98433 and 0.01821, respectively. Full article
(This article belongs to the Special Issue Advances in Welding and Mechanical Joining of Metals)
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15 pages, 10220 KiB  
Article
Process Optimization in Laser Welding of IN792 DS Superalloy
by Giuseppe Barbieri, Francesco Cognini, Chiara de Crescenzo, Alessandra Fava, Massimo Moncada, Roberto Montanari, Maria Richetta and Alessandra Varone
Metals 2024, 14(1), 124; https://doi.org/10.3390/met14010124 - 20 Jan 2024
Cited by 3 | Viewed by 1512
Abstract
Ni-base superalloys are employed to produce parts of aeronautic engines, space vehicles and power plants. During the production process or lifetime of components, cracks may occur which affect their performance. Reliable repairs can be carried out through high-energy density welding techniques. This work [...] Read more.
Ni-base superalloys are employed to produce parts of aeronautic engines, space vehicles and power plants. During the production process or lifetime of components, cracks may occur which affect their performance. Reliable repairs can be carried out through high-energy density welding techniques. This work investigated laser welding of the directionally solidified IN792 DS superalloy. The characteristics of the original material and their evolution in the base metal, heat-affected zone and melt zone after laser welding in different conditions and post-welding heat treatment were investigated through micro-hardness tests, light and scanning electron microscopy observations. The study allowed to optimize the process parameters and post-welding heat treatment, obtaining joints without macro-defects, such as cracks and pores, and with properties and microstructures of the melt zone like those of base metal. Full article
(This article belongs to the Special Issue Advances in Welding and Mechanical Joining of Metals)
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14 pages, 6509 KiB  
Article
Microstructural Evaluation of Inconel 718 and AISI 304L Dissimilar TIG Joints
by Dimitra Ioannidou, Michael Foinikaridis, Stavros Deligiannis and Petros E. Tsakiridis
Metals 2024, 14(1), 54; https://doi.org/10.3390/met14010054 - 31 Dec 2023
Cited by 1 | Viewed by 1884
Abstract
Dissimilar welding joints of Inconel 718 (IN718) nickel superalloy with low-carbon AISI 304L austenitic steel (SS304L) were conducted using the Tungsten Inert Gas (TIG) welding process. The present investigation focuses on the effect of different welding currents on the produced dissimilar joints’ microstructure [...] Read more.
Dissimilar welding joints of Inconel 718 (IN718) nickel superalloy with low-carbon AISI 304L austenitic steel (SS304L) were conducted using the Tungsten Inert Gas (TIG) welding process. The present investigation focuses on the effect of different welding currents on the produced dissimilar joints’ microstructure and mechanical properties. The microstructure study was carried out by light optical (LOM) and scanning electron microscopy (SEM), coupled with energy-dispersive spectroscopy (EDS) analysis. The nanoscale investigation was performed via a high-resolution transmission electron microscope (TEM). The mechanical behavior of the TIG joints was investigated via Vickers hardness testing. In all cases, the morphology and the microstructure of the fusion zone (FZ) and the corresponding heat-affected zones (HAZ) of the TIG-welded IN718 and SS304L verified the absence of porosity or other metallurgical defects. Except for carbides and carbonitrides, hard and brittle Laves phases ((FeNiCr)2(NbMoTiSi)) were also identified, which were dispersed in the interdendritic spaces in the form of elongated islands. Prolonged exposure to high temperatures and a slower cooling rate due to higher initial heat input led to the precipitates’ coarsening both in FZ and HAZ and, thus, to the consequent gradual embrittle of the dissimilar joints. Full article
(This article belongs to the Special Issue Advances in Welding and Mechanical Joining of Metals)
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10 pages, 5633 KiB  
Article
On the Heterogeneous Distribution of Secondary Precipitates in Friction-Stir-Welded 2519 Aluminium Alloy
by Ivan S. Zuiko, Sergey Malopheyev, Sergey Mironov, Sergey Betsofen and Rustam Kaibyshev
Metals 2022, 12(4), 671; https://doi.org/10.3390/met12040671 - 14 Apr 2022
Cited by 3 | Viewed by 1983
Abstract
The macro-scale distribution of secondary precipitates in friction-stir-welded 2519 aluminium alloy was studied. It was found that precipitation pattern essentially varied within the stir zone in terms of volume fraction, size, and even preferential concentration of the particles, either at grain boundaries or [...] Read more.
The macro-scale distribution of secondary precipitates in friction-stir-welded 2519 aluminium alloy was studied. It was found that precipitation pattern essentially varied within the stir zone in terms of volume fraction, size, and even preferential concentration of the particles, either at grain boundaries or within the grain interior. This effect was attributed to local variations in welding temperature and cooling rate, which led to complex precipitation phenomena including coarsening, dissolution, and partial reprecipitation. Specifically, the precipitation coarsening was most pronounced at the weld root due to the lowest welding temperature being in this area. On the other hand, the highest welding temperature at the upper weld surface enhanced the dissolution process. The reprecipitation phenomenon was deduced to be most prominent in the weld nugget due to the slowest cooling rate being in this microstructural region. Full article
(This article belongs to the Special Issue Advances in Welding and Mechanical Joining of Metals)
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