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Metals
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Advances in Welding Processes of Metallic Materials
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Advances in Welding Processes of Metallic Materials

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

Deadline for manuscript submissions: 25 February 2025 | Viewed by 3513

Special Issue Editor

Dr. Zhengwei Li

E-Mail Website
Guest Editor
State Key Laboratory of Precision Welding & Joining of Materials and Structures, Harbin Institute of Technology, Harbin, China
Interests: welding and joining; ultrasonic soldering; brazing; cavitation
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Welding and joining, as the earliest connection methods used by human beings, have been used for a very long time. Welding and joining are widely used in various fields and have received great attention in recent years due to the development of aviation, aerospace, nuclear energy, electronics and other new technologies.

This Special Issue, titled “Advances in Welding Processes of Metallic Materials”, welcomes welding and joining processes of all kinds of materials. The following aspects are considered: process optimization; experiments; simulation; metallurgical behavior; intermetallic compound; fracture behaviors of all joints welded/joined using all kinds of welding methods.

Dr. Zhengwei Li
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

  • welding
  • joining
  • soldering
  • joint
  • failure

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Published Papers (5 papers)

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Research

14 pages, 15193 KiB  
Article
Comparative Study on the Liquid Metal Embrittlement Susceptibility of the High-Si Advanced High-Strength Steel with EG and GA Zn Coatings
by Jingyi Gu, Jiayi Zhou, Rongxun Hu, Yu Sun, Ming Lei and Yulai Gao
Metals 2024, 14(11), 1221; https://doi.org/10.3390/met14111221 - 26 Oct 2024
Viewed by 533
Abstract
The Zn-coated high-Si advanced high-strength steel (AHSS) tends to suffer Zn-assisted liquid metal embrittlement (LME) during the resistance spot welding (RSW) process. In this study, the LME behaviors of electrogalvanized (EG) and galvannealed (GA) high-Si steels were comparatively investigated. The maximum lengths of [...] Read more.
The Zn-coated high-Si advanced high-strength steel (AHSS) tends to suffer Zn-assisted liquid metal embrittlement (LME) during the resistance spot welding (RSW) process. In this study, the LME behaviors of electrogalvanized (EG) and galvannealed (GA) high-Si steels were comparatively investigated. The maximum lengths of the LME cracks at the shoulder and center of the spot weld were approximately 366.6 μm and 1486.5 μm, respectively, for the EG yet 137.0 μm and 1533.3 μm, respectively, for the GA high-Si steels. Additionally, all EG and GA welded joints were etched to measure the nugget size. It was found that the increased welding current could aggravate the formation tendency of the LME cracks for both the EG and GA high-Si steels. Furthermore, the statistical results revealed that the electrogalvanized high-Si AHSS exhibited a relatively higher LME susceptibility than the galvannealed high-Si AHSS. It was deemed that the internal oxidation produced during the annealing before the Zn coating was the crucial factor that led to the difference in the LME susceptibilities for the EG and GA high-Si steels. Full article
(This article belongs to the Special Issue Advances in Welding Processes of Metallic Materials)
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15 pages, 12068 KiB  
Article
Formation of the Interlock Morphology and Its Role in Refill Friction Stir Spot Welding of Aluminum Alloy to Steel
by Tianhan Hu, Bolong Li, Zhen Li, Kai Ding, Tianhai Wu, Hua Pan and Yulai Gao
Metals 2024, 14(11), 1209; https://doi.org/10.3390/met14111209 - 23 Oct 2024
Viewed by 570
Abstract
Considering energy conservation and emission reductions, lightweight automobiles have become a research focus in the automotive industry. Steel/aluminum joining is regarded as an ideal lightweight structure, which can not only reduce the energy consumption but also ensure safety and is already attracting extensive [...] Read more.
Considering energy conservation and emission reductions, lightweight automobiles have become a research focus in the automotive industry. Steel/aluminum joining is regarded as an ideal lightweight structure, which can not only reduce the energy consumption but also ensure safety and is already attracting extensive attention. In this study, aluminum alloy 6061 and B410LA steel sheets were successfully joined by refill friction stir spot welding. The tensile properties, microhardness distribution and interfacial microstructure characteristics of the steel/Al welded joints were investigated. The maximum tensile load of the steel/Al joint was 4.3 kN. The mechanical properties of the steel/Al refill friction stir spot welded joint were largely determined by the bonding quality of the sleeve-plunging zone. With the stirring of the sleeve and the pin during the refill friction stir spot welding, work hardening occurred in the stir zone (SZ). The microhardness of the SZ was significantly higher than that of the steel base metal (BM) and could be detected on the steel side. The Fe-Al intermetallic compound (IMC) layer was continuously distributed at the interface of the sleeve-plunging zone, revealing good uniformity in the thickness. In particular, a hook-and-vortex-like structure formed during the refill friction stir spot welding process in the sleeve-plunging zone, producing a mechanical interlock effect at the interface. The ideal mechanical properties of the welded joint could be attributed to the good quality of the metallurgical and mechanical bonding at the interface, especially the mechanical interlock effect, thereby depending on the hook-and-vortex-like structure. Full article
(This article belongs to the Special Issue Advances in Welding Processes of Metallic Materials)
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14 pages, 10182 KiB  
Article
Effect of Ultrasound on Microstructure and Properties of Aluminum–Copper Friction Stir Lap Welding
by Wenzhen Zhao, Yalong Zhu, Zhaoxian Liu, Xiaoyang Yi, Jian Wang, Ao Fu, Fengyi Wang and Huan He
Metals 2024, 14(10), 1162; https://doi.org/10.3390/met14101162 - 11 Oct 2024
Viewed by 730
Abstract
In this paper, the influence mechanism of ultrasound on plastic flow and microstructure features of the aluminum–copper friction stir lap welding (Al/Cu-FSLW) process is systematically investigated by adjusting the welding speed and improving the shear rheology in the plastic stirring zone. Through adjusting [...] Read more.
In this paper, the influence mechanism of ultrasound on plastic flow and microstructure features of the aluminum–copper friction stir lap welding (Al/Cu-FSLW) process is systematically investigated by adjusting the welding speed and improving the shear rheology in the plastic stirring zone. Through adjusting the ultrasonic vibration and welding speed, the directional control of mechanical properties is realized. It is found that increasing the welding speed properly is beneficial to enhance the mechanical shear between the tool and the workpiece, thus forming more staggered layered structures at the copper side and improving the tensile strength of the weld. The acoustic softening enhances the viscoplastic fluid mixing and strengthens the mechanical interlock of the Al/Cu lap interface. As the welding speeds increase or ultrasonic vibration is applied, the thickness of Al/Cu intermetallic compound (IMC) decreases, and the tensile strength and elongation of the Al/Cu joints are enhanced. Compared with adjusting the welding speed, the ultrasonic vibration can further refine the copper particles which are stirred into the plastic zone, and the thinning effect of ultrasound on IMC layers is better than that of increasing welding speed. At the welding speed of 60 mm/min, the IMC layer thickness is reduced by 42% under ultrasonic effect. In three welding speed conditions, the UV reduced the absolute value of the effective heat of formation (EHF) for Al2Cu and Al4Cu9 and suppressed the formation of AlCu phase. Meanwhile, only when the welding speed is increased from 60 mm/min to 100 mm/min can the formation of AlCu be suppressed. Under the ultrasonic optimization, the stable improvement of welding efficiency is ensured. Full article
(This article belongs to the Special Issue Advances in Welding Processes of Metallic Materials)
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21 pages, 41273 KiB  
Article
Statistical Analysis-Based Prediction Model for Fatigue Characteristics in Lap Joints Considering Weld Geometry, Including Gaps
by Dong-Yoon Kim and Jiyoung Yu
Metals 2024, 14(10), 1106; https://doi.org/10.3390/met14101106 - 26 Sep 2024
Viewed by 514
Abstract
Automotive chassis components, constructed as lap joints and produced by gas metal arc welding (GMAW), require fatigue durability. The fatigue properties of the weld in a lap joint are largely determined by weld geometry factors. When there is no gap or a consistent [...] Read more.
Automotive chassis components, constructed as lap joints and produced by gas metal arc welding (GMAW), require fatigue durability. The fatigue properties of the weld in a lap joint are largely determined by weld geometry factors. When there is no gap or a consistent gap in the lap joint, improving the geometry of the weld toe can alleviate stress concentration and enhance fatigue properties. However, due to machining tolerances, it is difficult to completely eliminate or consistently manage the gap in the joint. In the case of a lap-welded joint with an inconsistent gap, it is necessary to identify the weld geometry factors related to fatigue properties. Evaluating the fatigue behavior of materials and welded joints requires significant time and cost, meaning that research that seeks to predict fatigue properties is essential. More research is needed on predicting fatigue properties related to automotive chassis components, particularly studies on predicting the fatigue properties of lap-welded joints with gaps. This study proposed a regression model for predicting fatigue properties based on crucial weld geometry factors in lap-welded joints with gaps using statistical analysis. Welding conditions were varied in order to build various weld geometries in joints configured in a lap with gaps of 0, 0.2, 0.5, and 1.0 mm, and 87 S–N curves for the lap-welded joints were derived. As input variables, 17 weld geometry factors (7 lengths, 7 angles, and 3 area factors) were selected. The slope of the S–N curve using the Basquin model from the S–N curve and the safe fatigue strength were selected as output variables for prediction in order to develop the regression model. Multiple linear regression models, multiple non-linear regression models, and second-order polynomial regression models were proposed to predict fatigue properties. Backward elimination was applied to simplify the models and reduce overfitting. Among the three proposed regression models, the multiple non-linear regression model had a coefficient of determination greater than 0.86. In lap-welded joints with gaps, the weld geometry factors representing fatigue properties were identified through standardized regression coefficients, and four weld geometry factors related to stress concentration were proposed. Full article
(This article belongs to the Special Issue Advances in Welding Processes of Metallic Materials)
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20 pages, 10782 KiB  
Article
Rear Weld Pool Thermal Monitoring in GTAW Process Using a Developed Two-Colour Pyrometer
by Vinicius Lemes Jorge, Issam Bendaoud, Fabien Soulié and Cyril Bordreuil
Metals 2024, 14(8), 937; https://doi.org/10.3390/met14080937 - 16 Aug 2024
Viewed by 708
Abstract
New systems and methods to access the temperature of the melt pool in welding processes have been developed to study phenomena, monitor behaviours, and even be used in closed-loop control strategies. Concerning arc welding processes, the arc radiation might impose a challenge to [...] Read more.
New systems and methods to access the temperature of the melt pool in welding processes have been developed to study phenomena, monitor behaviours, and even be used in closed-loop control strategies. Concerning arc welding processes, the arc radiation might impose a challenge to measure the temperature. However, heat input is the key point for welding quality. This work aims to evaluate the feasibility and detect potentialities of accessing the thermal field from the rear weld pool in the GTAW process by using in-house developed equipment. The original system was conceptualized based on a previous bichromatic method. Experiments were carried out with and without the wire feed addition, and welding parameters were varied to explore its impacts on the temperature measurement. A strategy to select the regions of interest (ROIs) within the weld pool was created, and the mean temperature was calculated and correlated to the weld bead features. This strategy was able to overcome the challenges imposed by the electrode/nozzle reflection and the arc radiation during the welding. The rear weld pool thermal field was shown to be an important source of data to provide hints of the weld bead features. The mean temperature can indicate geometrical changes in the weld bead. Furthermore, the technique has the potential to be used as a promising real-time process monitoring tool. Full article
(This article belongs to the Special Issue Advances in Welding Processes of Metallic Materials)
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Planned Papers

The below list represents only planned manuscripts. Some of these manuscripts have not been received by the Editorial Office yet. Papers submitted to MDPI journals are subject to peer-review.

Title: Numerical modeling of the process of connecting copper wires
Authors: Zygmunt Mikno; Janusz Pikuła
Affiliation: Lukasiewicz Research Network - Upper Silesian Institute of technology, Welding Centre

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