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Advanced Welding Technology in Metals II

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

Deadline for manuscript submissions: closed (31 December 2022) | Viewed by 35311

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Prof. Dr. João Pedro Oliveira

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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

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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.

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
arc welding
laser welding
welding
joining
characterization
mechanical properties

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Related Special Issues

Advanced Welding Technology in Metals in Metals (24 articles)
Advanced Welding Technology in Metals III in Metals (6 articles)

Published Papers (12 papers)

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Research

Jump to: Review

17 pages, 8963 KiB

Open AccessArticle

Effect of Liquid Metal Embrittlement Indent Cracks on Zinc Coated 3rd Generation AHSS Mechanical Performance

by Abdelbaset R. H. Midawi, Meet Patel, Mohammad Shojaee, Kate Pearson, Oleksii Sherepenko, Hassan Ghassemi-Armaki and Elliot Biro

Metals 2023, 13(3), 491; https://doi.org/10.3390/met13030491 - 27 Feb 2023

Cited by 4 | Viewed by 2023

Abstract

Third-generation advanced high-strength steels (3G-AHSS) are typically galvanized to prevent corrosion of the outer body structure. However, the zinc coating on the surface, combined with the locally elevated temperatures generated during the resistance spot welding (RSW) process, can provide the prerequisites for liquid metal embrittlement (LME). This work uses two strategies to control LME crack formation: current pulsation and varying the electrode geometry. These two methods were compared to a baseline welding schedule for a 3G-980-GI coated AHSS. The effectiveness of each method was discussed in terms of the overall weld cracking index and local cracking index. The results showed that increasing the current pulses results in a slower energy input into the weld, which can help to reduce LME crack formation. Introducing more pulses (five to seven pulses) reduced LME crack formation while maintaining the same welding time. Regarding the electrode geometry, the results showed an increase in LME cracking index for currents below the expulsion level Imax-10% when the electrode face diameter increased, whereas at the current level Imax-200A, the electrode radius was the most important factor to control LME crack index. For the current level above the expulsion, Imax+10%, a drastic decrease in the LME cracking index was observed when a large electrode surface diameter was used. The electrode radius was not a significant factor in controlling LME. The mechanical properties of selected conditions were examined using the lap shear test and the results showed no significant effect of LME cracks on the shear tensile strength. The location of the failure indicated that most of the cracks are located in the indented area (type A), which does not influence the lap shear strength. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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22 pages, 9470 KiB

Open AccessArticle

Features of Permanent Joints of Titanium (α+β)-Alloys Obtained by Friction Stir Welding Using a Nickel Superalloy Tool

by Alihan Amirov, Andrey Chumaevskii, Nikolay Savchenko, Denis Gurianov, Aleksandra Nikolaeva, Vladimir Krasnoveykin, Aleksey Ivanov, Valery Rubtsov and Evgeny Kolubaev

Metals 2023, 13(2), 222; https://doi.org/10.3390/met13020222 - 24 Jan 2023

Cited by 8 | Viewed by 1690

Abstract

Titanium alloys are widely used in industry, especially (α+β)-alloys, among which Ti-6Al-4V alloy is the most popular one. Another common alloy that often appears in patents for titanium products is Ti-4Al-3Mo-1V. Here, we investigate welded joints of (α+β)-alloy Ti-4Al-3Mo-1V obtained by friction stir welding (FSW) using a working tool made of nickel-based heat-resistant alloy ZhS6U. In addition, welded joints of Ti-6Al-4V and Ti-4Al-3Mo-1V alloys with similar mechanical characteristics were considered. Mechanical tests showed that the obtained joints had a tensile strength greater than that of the base metal. This result was achieved in the welding mode where the axial load was varied during the welding process. X-ray diffraction analysis revealed a change in the phase structure of the welded joint. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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23 pages, 6989 KiB

Open AccessArticle

Welding of Low Carbon Steel Tubes Using Magnetically Impelled Arc Butt Welding: Experimental Investigation and Characterization

by Mukti Chaturvedi, Arungalai Vendan Subbiah, Mohammed Y. Tharwan, Sharaf Al Sofyani, Vladimir Kachinskiy, Sharanabasavaraj Radder, Ashraff Ali Kaveripakkam Suban, Essmat Showman, M. Fattouh and Ammar H. Elsheikh

Metals 2022, 12(11), 1965; https://doi.org/10.3390/met12111965 - 17 Nov 2022

Cited by 5 | Viewed by 2099

Abstract

Magnetically impelled arc butt (MIAB) welding is a solid-state technique of welding that utilizes the heating effect of a high-speed rotating arc for the formation of the weld. The process exhibits lower time and power consumption compared to conventional solid-state processes for tube–tube joining. However, the available research reports on MIAB welding of Mild Steel (MS)1018 are still inadequate and lack the details required for extending the applications of this process. Hence, this study was undertaken to investigate MIAB welding for MS 1018 tubes. Experimental investigations were performed on a specifically designed and newly fabricated MIAB welding machine. The experimental trials involved varying the process parameters and understanding their influence on joint strength and other weld characteristics. Microstructure of the MIAB weld consisted of acicular ferrite which differed from the microstructure of the heat-affected zone. These trials helped to arrive at the optimum parametric window that specified the ranges of key parameters viz. welding current, upset current, and welding time to yield an efficient weld. Chemical analysis of the weld indicated the absence of inter-metallics. MIAB welding of MS1018 showed greater strength and integrity at the joint when optimum ranges of the process parameters were maintained, and is feasible for deployment as economizer coils in boilers, pressure part tubes, and automobile tubular component joining applications. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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14 pages, 6113 KiB

Open AccessArticle

Fabrication and Characterization of Wire Arc Additively Manufactured AlSi5 Structures

by Georgi Kotlarski, Maria Ormanova, Ralf Ossenbrink, Alexander Nikitin, Nikolay Doynov, Stefan Valkov and Vesselin Michailov

Metals 2022, 12(11), 1870; https://doi.org/10.3390/met12111870 - 2 Nov 2022

Cited by 5 | Viewed by 2272

Abstract

For the purpose of this research, single track details were manufactured in the shape of thin walls with a length of 100 mm and a height of 80 mm. Two welding speeds were chosen for this experiment–13.3 mm/s and 20.0 mm/s corresponding to the following heat inputs: 120 J/mm and 80 J/mm. The gas metal arc welding (GMAW) method was used for the build-up of the specimens in the cold arc pulse mode. The structure of the specimens was studied using X-ray diffraction (XRD) analysis carried out with CuKα radiation with a wavelength of 1.5406 Ǻ, optical microscopy, scanning electron microscopy (SEM), and energy dispersive X-ray spectroscopy (EDX). Furthermore, the Vickers hardness of the samples was determined using a ZwickRoell DuraScan 10/20 G5 unit at a force of 1 N. A preferred crystallographic orientation towards the (200) plane was observed in all cases, however a vastly textured structure was observed with inclusions of peaks in the (111), (220), and (311) crystallographic planes. The full width at half maximum (FWHM) of samples taken from different stages of build-up was calculated indicating an increase of the dislocation density at the more advanced stages of specimen growth. Despite that an increase of the hardness was observed towards the top of both specimens. This is attributed to the change in the structure of the αAl + Si formations from an irregular one at the bottom of the specimens, towards a fibrous one at the top. The results are discussed in regard to the optimization of the build-up process during wire arc additive manufacturing (WAAM). Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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23 pages, 28071 KiB

Open AccessArticle

Metallographic Study of Overlapped Laser Welds of Dissimilar Materials

by Anna Guzanová, Erik Janoško, Dagmar Draganovská, Ján Viňáš, Miroslav Tomáš, Janette Brezinová, Silvia Maláková, Miroslav Džupon and Marek Vojtko

Metals 2022, 12(10), 1682; https://doi.org/10.3390/met12101682 - 9 Oct 2022

Cited by 2 | Viewed by 1958

Abstract

The paper deals with the metallographic analysis of overlapped laser welds of dissimilar materials based on galvanized and ungalvanized steels in various combinations. In addition to a gallery of metallographic sections, the paper presents the monitoring of weld defects, the measurement of selected weld geometrical characteristics and changes in weld microstructure by measuring the microhardness profile across the joint. The mixing of materials was monitored by area and line EDX analysis in the melting zone. Subsequently, the load carrying capacity of the formed joints was determined and compared with FEM simulation. Finally, the dependences of hardness and strength of welds on carbon content and carbon equivalent were determined. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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15 pages, 10670 KiB

Open AccessEditor’s ChoiceArticle

The Microstructure and Mechanical Properties of 5083, 6005A and 7N01 Aluminum Alloy Gas Metal Arc-Welded Joints for High-Speed Train: A Comparative Study

by Laijun Wu, Biao Yang, Xiaohui Han, Guolong Ma, Bingxiao Xu, Yuhang Liu, Xiaoguo Song and Caiwang Tan

Metals 2022, 12(2), 213; https://doi.org/10.3390/met12020213 - 24 Jan 2022

Cited by 19 | Viewed by 5077

Abstract

This study aimed to conduct a comparative study on the microstructure and mechanical performance of 5083, 6005A and 7N01 Al joints used in China Railway High-speed (CRH) trains. We connected 10 mm-thick plates by three-layer and three-pass gas metal arc welding (GMAW). The results indicated that 6005A and 7N01 Al joints were more sensitive to grain boundary liquation in the partially melted zone (PMZ) than 5083 Al joins. Besides, recrystallization was obtained in heat-affected zones (HAZ). The 5083 Al joints experienced the most severe recrystallization and the grain size changed from 6.32 (BM) to 32.44 (HAZ) μm duo to intracrystalline strain induced by cold-rolled processes. The 7N01 Al alloys experienced the lowest extent of recrystallization and the grain size increased from 5.32 (BM) to 22.31 (HAZ) μm. Furthermore, significant precipitate evolution in the HAZ was observed. Original thin β” precipitates dissolved in HAZ of 6005A Al joints and transformed to the softer β phase. However, less precipitation transition was examined in 5083 and 7N01 Al joints. The precipitates’ evolution produced a softening region in HAZ of 6005A joints where the hardness was only 55 HV. The microhardness profile of the other two Al joints was less affected. The tensile strength of 5083, 6005A, and 7N01 Al alloy joints reached 323, 206 and 361 MPa, respectively. The 5083 Al and 6005A Al joints failed at HAZ near the fusion line while 7N01 Al joints failed at the fusion zone owing to the high strength of the base metal. The liquation, coarse grains by recrystallization, and precipitate evolution all decreased local strength, resulting in the fracture at HAZ. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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11 pages, 4635 KiB

Open AccessArticle

The Influence of the Mechanism of Double-Sided FSW on Microstructure and Mechanical Performance of AZ31 Alloy

by Suna Cha, Hongliang Hou and Yanling Zhang

Metals 2021, 11(12), 1982; https://doi.org/10.3390/met11121982 - 9 Dec 2021

Viewed by 2153

Abstract

In the friction stir welding (FSW) process, the final performance of weld joints is determined by microstructures influenced mainly by the heat input and mechanical deformation. In this research, the effects of FSW parameters, rotation speeds, and welding passes, on microstructure and mechanical properties of AZ31 alloy were systematically and comparatively studied. It was found that the microstructure at the joint center with multi-pass FSW could obtain a smaller average grain size compared with the single pass. The differences of the grain size were reduced significantly when the samples experienced the double-side FSW process. The mechanical performance results showed that the optimum strength (315 MPa) was achieved through the double-side FSW process with a rotation speed of 500 r/min and welding speed of 60 mm/min. The mechanism of the parameters and double-sided process on mechanical properties of the joint samples was elaborated. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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13 pages, 6497 KiB

Open AccessFeature PaperArticle

Dissimilar Laser Welding of a NiTi Shape Memory Alloy to Ti₂AlNb

by Fuguo Ge, Bei Peng, João Pedro Oliveira, Wenchao Ke, Fissha Biruke Teshome, Yongmei Li and Zhi Zeng

Metals 2021, 11(10), 1578; https://doi.org/10.3390/met11101578 - 4 Oct 2021

Cited by 8 | Viewed by 2551

Abstract

NiTi-based shape memory alloys and the Ti₂AlNb alloy have gained increasing importance in the aerospace field. The joining of these two materials can further increment the importance and usage of these relevant engineering materials and expand their potential applications. However, when joining NiTi-based shape memory alloys to Ti-based alloys, the formation of brittle Ti-rich intermetallic compounds often occurs, significantly limiting their functionality and use. Dissimilar joints between a NiTi shape memory alloy and Ti₂AlNb alloy were obtained using a 0.1 mm thick Niobium (Nb) interlayer via laser welding. By process optimization, sound joints were obtained. The microstructure evolution was assessed by means of electron microscopy, whereas the mechanical strength of the joints was evaluated using lap shear tensile testing. The best performing joints were seen to fracture at maximum loads above 1230 N, thus allowing us to consider this dissimilar pair for structural applications. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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12 pages, 15546 KiB

Open AccessEditor’s ChoiceArticle

Ultrasonic Metal Welding of Multilayered Copper Foils to Nickel-Plated Copper Sheet in Lithium-Ion Battery Cell

by Seungmin Shin, Sangwoo Nam, Jiyoung Yu, Jiyong Park and Dongcheol Kim

Metals 2021, 11(8), 1195; https://doi.org/10.3390/met11081195 - 27 Jul 2021

Cited by 16 | Viewed by 5142

Abstract

The battery performance of electric vehicles depends on the density and capacity of the battery; thus, the battery cells must be assembled in as many layers as possible. Electric vehicle batteries are typically composed of several cells which form modules connected by busbars, with dozens of modules manufactured as battery packs. The ultrasonic metal welding (UMW) technology is applied to such multilayered foil welding. This study analyzed UMW to ensure the weldability of multilayered Cu foils and a Ni-plated Cu strip in lithium-ion battery cells through various approaches. In UMW, the effect of the alignment on weld production and quality were examined through the energy and mechanical performance of the weld by conducting comparative experiments on the alignment of the horn and anvil. Additionally, the effects of UMW process parameters, such as the welding pressure, amplitude, and welding time, were statistically analyzed. The weldability evaluation and characteristic analysis were performed based on these variables. Furthermore, the cross-sectional shapes and microstructure behavior of the Ni layers were analyzed based on the weld quality. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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11 pages, 6118 KiB

Open AccessArticle

A Unified Adjustment Model for Gaussian Pulse Welding on Aluminum Alloys

by Qiang Zhu, Ping Yao, Xiaoyan Yu, Bin Xie, Jiaxiang Xue and Haibiao Hu

Metals 2021, 11(4), 671; https://doi.org/10.3390/met11040671 - 20 Apr 2021

Viewed by 2041

Abstract

To solve the challenge of welding aluminum alloys, a unified adjustment model for Gaussian pulse welding is established. This model can achieve improved welding performance by adjusting the base current of the weak pulse group within a specific range of average welding current inputs. The flat overlaying welding is carried out on the base material: 6061 aluminum alloys with thicknesses of 2 mm, 3 mm, and 5 mm. A stable welding process, indicated by reduced spatter, is produced, with a soft arc sound and good repeatability in the waveforms of the real-time current and voltage. The weld has a shiny surface and regular fish scale ripples. Metallographic analysis shows that the fusion line is clear, and there are no visible defects, while the weld zone has fine dendritic structures. The tensile test results indicate that fractures occur in the heat-affected zone, and that the tensile strength reaches about 68% of that of the base metal. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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Review

Jump to: Research

32 pages, 13176 KiB

Open AccessReview

A Review on Ultrafast Laser Microwelding of Transparent Materials and Transparent Material–Metals

by Jiayi Xu, Qing Jiang, Jin Yang, Jiangmei Cui, Yixuan Zhao, Min Zheng, J. P. Oliveira, Zhi Zeng, Rui Pan and Shujun Chen

Metals 2023, 13(5), 876; https://doi.org/10.3390/met13050876 - 1 May 2023

Cited by 9 | Viewed by 3094

Abstract

Transparent hard and brittle (THB) materials have generated significant interest due to their excellent properties, such as wide spectral transmittance, heat resistance, chemical inactivity and high mechanical strength. To further explore the application of THB materials, it is inevitable to be confronted with a range of joining THB materials and THB material–metals. Ultrafast (UF) laser microwelding enables a new means of joining THB materials and THB material–metals, due to a localized energy deposition method, which is dominated by nonlinear absorption. This process can realize high-quality micro-zone direct joining of THB materials or THB material–metals without the assistance of a light-absorbing intermediate layer. In this paper, we review the advances in UF laser microwelding of THB materials and THB material–metals considering the last two decades, from the analysis of the interaction mechanism between UF laser and matter to the key influencing factors and practical applications of this technology. Finally, the existing problems and the future research focus of UF laser microwelding technology of THB materials and THB material–metals are discussed. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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19 pages, 7048 KiB

Open AccessReview

A Short Review on the Corrosion Behaviour of Wire and Arc Additive Manufactured Materials

by Davi Alves Marques, João Pedro Oliveira and Ana Catarina Baptista

Metals 2023, 13(4), 641; https://doi.org/10.3390/met13040641 - 23 Mar 2023

Cited by 35 | Viewed by 3532

Abstract

Wire and Arc Additive Manufacturing (WAAM) is a deposition rate process for the creation and/or repair of large structural metallic components. The non-equilibrium heating and cooling conditions associated with WAAM lead to the development of heterogenous microstructures. Although there is a large body of work focusing on the microstructure and mechanical properties of WAAM-fabricated components, assessment of the corrosion behaviour of alloys fabricated by WAAM is still in its infancy. In this review, the current body of knowledge associated with the corrosion behaviour of different WAAM-fabricated engineering alloys is presented and discussed. Future perspectives and potential research topics are also presented. This is the first review work focusing on the corrosion of wire and arc additive manufactured materials. Full article

(This article belongs to the Special Issue Advanced Welding Technology in Metals II)

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