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Metals
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Advanced Welding Technology in Metals III
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Advanced Welding Technology in Metals III

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

Deadline for manuscript submissions: closed (31 October 2024) | Viewed by 8806

Special Issue Editors

Prof. Dr. João Pedro Oliveira

E-Mail Website
Guest Editor
CENIMAT/I3N, Department of Materials Science, NOVA School of Science and Technology, Universidade NOVA de Lisboa, 2829-516 Caparica, Portugal
Interests: advanced characterization; martensitic transformation; thermomechanical processing; welding; synchrotron radiation; additive manufacturing
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Zhi Zeng

E-Mail Website
Guest Editor
School of Mechanical and Electrical Engineering, University of Electronic Science and Technology of China, No.2006, Xiyuan Ave, West Hi-Tech Zone, Chengdu, China
Interests: laser welding; shape memory alloys; numerical modeling; stress and distortion; fatigue
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Welding and joining technologies are fundamental in advanced engineering alloys to expand their applications. At present, we often observe significant developments in the areas of welding and joining, with more complex and sophisticated variants available. Another key area of interest is related to welding metallurgy: The microstructural changes induced by welding and joining techniques can drastically modify the joints’ mechanical behavior. For that reason, it is necessary to correlate process parameters, microstructure, and mechanical response in welded joints. Finally, simulation and modelling of the thermomechanical behavior during welding and the predictions of existing phases due to the weld thermal cycle are critical to optimize welding parameters.

This special issue is the 3rd volume of series special issues related to welding. In the first volume “Advanced Welding Technology in Metals”, 24 published papers are collected, and for the 2nd volume “Advanced Welding Technology in Metals II”, 11 published papers are collected.

For this Special Issue, we invite our colleagues to submit papers in the areas of welding and joining. The topics of interest include but are not limited to similar and dissimilar joining, fusion and solid-state processes, modeling and simulation, process development, and advanced characterization. Review papers and short communications are also of interest to this Special Issue.

Prof. Dr. João Pedro Oliveira
Prof. Dr. Zhi Zeng
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. 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
  • explosion welding
  • friction stir welding
  • arc welding
  • laser welding
  • welding
  • joining
  • characterization
  • mechanical properties

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Related Special Issue

Published Papers (6 papers)

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Research

26 pages, 7341 KiB  
Article
The Effect of Energy Parameters of Power Sources on the Structure and Properties of Permanent Joints at Manual Arc Welding
by Dmitry P. Il’yashchenko, Dmitry A. Chinakhov and Elena V. Lavrova
Metals 2024, 14(7), 759; https://doi.org/10.3390/met14070759 - 27 Jun 2024
Cited by 1 | Viewed by 810
Abstract
The study presents the results of the research into the effect of the dynamic properties of inverter and diode power sources of welding arc power supply on the stability of melting and transfer of electrode metal into the weld pool. The principal energy [...] Read more.
The study presents the results of the research into the effect of the dynamic properties of inverter and diode power sources of welding arc power supply on the stability of melting and transfer of electrode metal into the weld pool. The principal energy parameters of the power source include the rates of rise and fall of short-circuit current, the ratio of arc burning current to short-circuit current, and other related factors. It has been demonstrated that an increase in the rate of change of these parameters within one welding mode microcycle alters the properties of heat and mass transfer, increases the frequency of electrode metal droplet transfer, reduces the size of transferred droplets in the weld pool and the duration of their stay on the electrode end under the influence of the high temperature of the welding arc, and the duration of short circuits. The increase in the mass fraction of alloying elements at their transition from the coated electrode to the weld metal is demonstrated to depend on the rate of change of the main energy parameters of one welding mode microcycle of the inverter power source in comparison with the diode rectifier. An enhancement in the structural integrity and properties of permanent joints during welding has been observed when using an inverter power source for the welding arc with high dynamic properties. Full article
(This article belongs to the Special Issue Advanced Welding Technology in Metals III)
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16 pages, 27791 KiB  
Article
Tailoring Weldability for Microstructures in Laser-Welded Near-α Titanium Alloy: Insights on Mechanical Properties
by Shiwei Zhang, Baoqiang Cong, Zhi Zeng, Ying Liu and Lu Chai
Metals 2024, 14(6), 690; https://doi.org/10.3390/met14060690 - 11 Jun 2024
Viewed by 1038
Abstract
With the development of lightweight aerospace structures, the use of the high-quality and efficient laser welding of near-α titanium alloys has received widespread attention and favor thanks to its superior comprehensive performance. The welding experiment of 3 mm thick TA15 titanium alloy was [...] Read more.
With the development of lightweight aerospace structures, the use of the high-quality and efficient laser welding of near-α titanium alloys has received widespread attention and favor thanks to its superior comprehensive performance. The welding experiment of 3 mm thick TA15 titanium alloy was carried out by YAG laser welding, and the material weldability, microstructure, microhardness, and mechanical properties of welded joints were systematically studied. The results indicated that laser welding of TA15 titanium alloy can produce well-formed welded joints without defects such as cracks and porosity. The welded metal used was a typical basket-weave microstructure composed of a large number of α′ martensitic phases and a small number of high-temperature residual β phases, and the heat-affected zone was a staggered arrangement of undissolved α phase and needle-like α′ martensite. The microhardness of the welded joint showed a hump distribution, and the hardness of WM fluctuated between 410 and 450 HV since the martensitic transformation occurred during the solidification of the weld under thermal cycling, and the β phase changed to the needle-like α′ phase. The tensile test indicated that the fracture position was located in the base metal area, and the fracture morphology showed the equiaxial dimple morphology of different sizes in a ductile fracture mode. The welded metal had the lowest impact performance (average value of 5.3 J) because the weld area was predominantly coarse α′ martensite. This experiment conducted systematic, in-depth, and extensive research on welding processes, hardness, tensile, impact, and fracture mechanisms. Based on the special product applications in the aerospace field, it was more targeted and conducive to promoting the application of the welding process in this material. Full article
(This article belongs to the Special Issue Advanced Welding Technology in Metals III)
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22 pages, 6977 KiB  
Article
Enhancing Mechanical Characteristics of 6061-T6 with 5083-H111 Aluminum Alloy Dissimilar Weldments: A New Pin Tool Design for Friction Stir Welding (FSW)
by Wazir Hassan Khalafe, Ewe Lay Sheng, Mohd Rashdan Bin Isa and Shazarel Bin Shamsudin
Metals 2024, 14(5), 534; https://doi.org/10.3390/met14050534 - 30 Apr 2024
Viewed by 1492
Abstract
This research addresses the escalating need for lightweight materials, such as aluminum and magnesium alloys, in the aerospace and automotive sectors. The study explores friction stir welding (FSW), a cost-efficient process known for producing high-quality joints in these materials. The experiment involved the [...] Read more.
This research addresses the escalating need for lightweight materials, such as aluminum and magnesium alloys, in the aerospace and automotive sectors. The study explores friction stir welding (FSW), a cost-efficient process known for producing high-quality joints in these materials. The experiment involved the welding of dissimilar aluminum alloys (AA5086-H111 to AA6061-T6) using a novel pin tool design with welding parameters such as holding time, pin tool length, tool spindle speed, and linear speed fine-tuned through a design of experiment (DOE) approach. A comparative analysis of two tool designs revealed that the newly introduced design substantially improved mechanical properties, particularly tensile strengths, by 18.2% relative to its predecessor. It is noteworthy that FSW joint efficiency is 83% when using a normal tool design in comparison with 92.2% when using a new tool design at similar FSW parameters. The new tool achieved the parameter values leading to the maximum tensile strength of 317 MPa with 3 mm thickness (Th), 25 s holding time (Tt), 0.1 mm dimension (L), 1600 rpm spindle speed (SS), and 30 mm/min feed velocity (Fr). In comparison, the normal tool achieved a maximum UTS of 285 MPa, 5 mm Th, 25 s Tt, 0.3 mm L, 800 rpm SS, and 90 mm/min Fr. The new tool design, with longitudinal and circular grooves, improves heat input for plastic deformation and alloy mixing during welding. Subsequent analysis of the joint’s microstructure and microhardness shows its similarity to the original alloys. Full article
(This article belongs to the Special Issue Advanced Welding Technology in Metals III)
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15 pages, 8950 KiB  
Article
Research of a Novel Non-Axisymmetric Side-Compressed Variable Polarity Plasma Arc and Its Pressure Distribution Characteristics
by Hongxing Zhao, Chunli Yang and Chenglei Fan
Metals 2024, 14(2), 231; https://doi.org/10.3390/met14020231 - 14 Feb 2024
Cited by 1 | Viewed by 1079
Abstract
In the keyhole variable polarity plasma arc weldng (VPPAW) process at horizontal position, the metal driven by gravity gathered on one side of the molten pool, and the weld formation is difficult, especially for thick workpiece welding. A specially designed experiment to analyze [...] Read more.
In the keyhole variable polarity plasma arc weldng (VPPAW) process at horizontal position, the metal driven by gravity gathered on one side of the molten pool, and the weld formation is difficult, especially for thick workpiece welding. A specially designed experiment to analyze the influence of gravity on weld formation and a novel nozzle structure with side holes was proposed to generate a novel non-axisymmetric side-compressed plasma arc and redistribute arc pressure. The arc shape and pressure distribution were studied, and the ratio of difference for arc pressure in different directions Rp was introduced to evaluate the effects of non-axisymmetric side compression for the plasma arc. The results indicate that the non-axisymmetric distributed side holes reshape the plasma arc both in the EN and EP phases. The pressure of the non-axisymmetric side-compressed plasma arc decreases relatively strongly in one direction (direction b) and relatively weakly in the other direction (direction a). Rp is significant at 1 mm to 5 mm from the arc center, with a relatively large Rp within this range. The compression effect is enhanced with an increase in welding current or plasma gas flow rate, and Rp increases from 24% to 49% as the plasma gas flow rate increases from 2 L/min to 4.5 L/min. Specially designed validation experiments confirm that the new plasma arc significantly affects the weld formation in keyhole VPPAW process. An aluminum alloy workpiece with 8 mm thickness and no groove preparation was welded by the novel plasma arc in a horizontal welding position, and the weld is well formed. Full article
(This article belongs to the Special Issue Advanced Welding Technology in Metals III)
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20 pages, 7492 KiB  
Article
Brazing of Copper Pipes for Heat Pump and Refrigeration Applications
by António B. Pereira, João M. S. Dias, José P. Rios, Nélia M. Silva, Sathishkumar Duraisamy and Ana Horovistiz
Metals 2024, 14(2), 171; https://doi.org/10.3390/met14020171 - 30 Jan 2024
Cited by 1 | Viewed by 2419
Abstract
In heat pumps and refrigeration systems, copper parts play a crucial role. Since heat pumps for space and water heating work under high pressure and are susceptible to vibrations, it is crucial to perfectly weld the copper pipes and heat exchangers to avoid [...] Read more.
In heat pumps and refrigeration systems, copper parts play a crucial role. Since heat pumps for space and water heating work under high pressure and are susceptible to vibrations, it is crucial to perfectly weld the copper pipes and heat exchangers to avoid system failures and prevent the leakage of the circulating refrigerants, which are harmful to the environment. The welding of the copper pipes is usually performed by the brazing process in a furnace. The components are subjected to a period of approximately 50 min inside a continuously open oven, varying the temperature from 710 °C to 830 °C. The oven inlets and outlets are protected by nitrogen curtains to guarantee a suitable internal environment and prevent the contamination of the gas inside the oven. This work analyses which welding methods are most suitable for welding copper, the best joint shape, process time, brazing specimens of a copper alloy, tightness tests, and mechanical properties and composition of the welding samples. From the tests carried out, the appearance of small and large defects is reduced by using a 1 mm thick external ring of filler material and a brazing temperature of 820 °C. Full article
(This article belongs to the Special Issue Advanced Welding Technology in Metals III)
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21 pages, 15693 KiB  
Article
Durability of Single Lap Friction Stir Welded Joints between S355-J0 Steel and AA5083 Aluminum Alloy–Mechanical Tests
by Borsellino Chiara, Federica Favaloro and Guido Di Bella
Metals 2024, 14(2), 137; https://doi.org/10.3390/met14020137 - 23 Jan 2024
Cited by 1 | Viewed by 1239
Abstract
This study aims to investigate a friction stir welded joint between steel and aluminum alloy. FSW is nowadays one of the most interesting joining techniques due to the possibility of connecting materials and thicknesses that are difficult or impossible to weld with traditional [...] Read more.
This study aims to investigate a friction stir welded joint between steel and aluminum alloy. FSW is nowadays one of the most interesting joining techniques due to the possibility of connecting materials and thicknesses that are difficult or impossible to weld with traditional techniques. The main advantage is that materials are not affected by thermal cycle problems during solidification and cooling, and the absence of fumes and pollution during the process favors the quality of the welded joint. The life of metal joints could be greatly reduced in a corrosive environment since the less noble material will tend to increase its corrosion rate, while the nobler one will reduce its electrochemical dissolution. Accelerated aging tests (i.e., salt fog test) are used to estimate the lifetime of metal joints in highly aggressive environments. The aim of the present work is to evaluate the durability at a long aging time in the salt spray test (according to ASTM B117) of carbon steel/aluminum alloy joints, obtained by FSW. In this first part, mechanical test results are reported. A deep metallographic and chemical investigation is going to be reported in part two. The current research work investigates the welding direction and residence time in the salt spray chamber. The breakage of all tested samples, evaluated after the tensile tests were carried out, always occurs at the interface of the joint, regardless of the change of direction of the weld on the advancing or retreating side. The welding direction influences the breakage of the joint only before the aging treatment. Specifically, specimens produced in advance are characterized by increased joint strength. On the other hand, the factor that influences the performance of the joints is the exposure time where, starting from the first point of aging, i.e., after two months, there is a decrease in the maximum load of 40%, and the effect of corrosion leads to a significant deterioration of the weld which remains almost similar until the last point of aging. Full article
(This article belongs to the Special Issue Advanced Welding Technology in Metals III)
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