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Metals
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Advances in Dissimilar Welding and Joining
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Advances in Dissimilar Welding and Joining

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

Deadline for manuscript submissions: closed (30 April 2023) | Viewed by 14395

Special Issue Editor

Dr. Paolo Ferro

E-Mail Website
Guest Editor
Department of Engineering and Management, University of Padova, Stradella San Nicola 3, 36100 Vicenza, Italy
Interests: raw materials; structural integrity of welded joints and additively manufactured components; welding and heat treatment simulation; cast iron; stainless steels; materials selection
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

I am very happy to inform you of the launch of a Special Issue named ‘Advance in Dissimilar Welding and Joining’ by the journal Metals. The need for joining dissimilar metallic materials is of primary importance in the design of components. This is because we are living in the era of multi-materials, where lightweight solutions or materials with enhanced mechanical and thermal properties are achieved by combinations of different materials and used in sectors such as the shipping, aviation, and automobile industries. The joining of dissimilar materials is very challenging, since mismatches between physical, chemical, thermal, and mechanical properties can tremendously impact the goal of obtaining a sound joint. This Special Issue aims to collect new advances in this research field. Therefore, due to your expertise in the field, I invite you to submit works focusing on the welding and joining of dissimilar metallic materials.

Prof. Dr. Paolo Ferro
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

  • Dissimilar welding
  • Microstructure
  • Mechanical properties
  • Modeling
  • Dissimilar joining
  • Thermal properties
  • Corrosion resistance
  • Fatigue

     

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Published Papers (6 papers)

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Research

23 pages, 5830 KiB  
Article
Process Modelling Applied to Aluminium-Steel Butt Welding by Hybrid Metal Extrusion and Bonding (HYB)
by Francesco Leoni, Øystein Grong, Ambra Celotto, Hallvard Gustav Fjær, Paolo Ferro and Filippo Berto
Metals 2022, 12(10), 1656; https://doi.org/10.3390/met12101656 - 30 Sep 2022
Cited by 6 | Viewed by 1841
Abstract
In the present investigation, the numerical code WELDSIM is used to simulate butt welding of 4 mm thick plates of S355 steel and AA6082-T6 by Hybrid Metal Extrusion and Bonding (HYB). This is a new solid state joining process using continuous extrusion as [...] Read more.
In the present investigation, the numerical code WELDSIM is used to simulate butt welding of 4 mm thick plates of S355 steel and AA6082-T6 by Hybrid Metal Extrusion and Bonding (HYB). This is a new solid state joining process using continuous extrusion as a technique to enable aluminium filler metal additions. In WELDSIM, the finite element heat flow model is coupled to a frictional heating model, an isokinetic diffusion model for the interfacial intermetallic compound (IMC) formation and a nanostructure model for simulating reversion and re-precipitation of hardening phases inside the aluminium part of the joints during welding and subsequent natural ageing. The HYB process model is validated by comparison with experimental data obtained from in-situ thermocouple measurements and hardness testing carried out on three different Al-steel butt welds. Furthermore, scanning electron microscope examinations of the Al-steel interfaces have been conducted to check the predicted power of the IMC diffusion model. It is concluded that the process model is sufficiently relevant and comprehensive to be used in simulations of both the thermal, microstructure, and strength evolutions fields in these dissimilar butt welds. Some practical applications of the process model are described toward the end of the article, where particularly its potential for optimising the load-bearing capacity of the joints, is highlighted. Full article
(This article belongs to the Special Issue Advances in Dissimilar Welding and Joining)
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13 pages, 7083 KiB  
Article
Characteristics of the Dissimilar AA7075 and Q235 Steel Joints Fabricated by Friction Stir Welding
by Yu Chen and Fenghe Zhang
Metals 2022, 12(8), 1376; https://doi.org/10.3390/met12081376 - 19 Aug 2022
Cited by 5 | Viewed by 1678
Abstract
In this study, dissimilar AA7075/Q235 steel joints were successfully fabricated by friction stir welding (FSW), and the grains of AA7075 in the nugget zone (NZ) were refined and mixed with the broken Q235 fragments (i.e., the steel particles, strips, and blocks). Meanwhile, intermetallic [...] Read more.
In this study, dissimilar AA7075/Q235 steel joints were successfully fabricated by friction stir welding (FSW), and the grains of AA7075 in the nugget zone (NZ) were refined and mixed with the broken Q235 fragments (i.e., the steel particles, strips, and blocks). Meanwhile, intermetallic compound (IMC) layers were generated along the aluminum/steel (Al/steel) interface due to the occurrence of Al/steel diffusion. The results also revealed that the macro- and microstructures of the FSW joints varied depending on the welding heat input; under the cold FSW condition, micro-defects formed because of the weak and chaotic material flow in the NZ, reducing the welding heat input gave rise to inhomogeneous grain refinement; and the dynamic recrystallization of Al only occurred in the regions that lacked large steel blocks. In contrast, elevating the welding heat input led to the homogenization of the grain refinement and increased the thickness of the IMC layers. The FSW quality was controlled by both the thickness of the IMC layers and the size of the steel fragments simultaneously. Both the optimal-thickness IMC layers (about 2 μm) and fine steel particles were required to strengthen the joints, and a more than 30 MPa increment in the tensile strength could be obtained by manufacturing the above microstructures. Unfortunately, all the FSW joints failed in a brittle manner and the elongation was lower than 5%. Two kinds of fracture surfaces were observed inside the NZ: one was flat along the Al/steel interface, and the other was uneven due to the pulling out of the large steel strips and blocks. Full article
(This article belongs to the Special Issue Advances in Dissimilar Welding and Joining)
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16 pages, 8331 KiB  
Article
Effect of Rotation Speed on Microstructure and Mechanical Properties of Continuous Drive Friction Welded Dissimilar Joints of 6061-T6 Al and Copper
by Xianyong Zhu, Yuexiang Fan, Liangwen Xie, Xiong Xiao, Peng Wang, Song Yang and Cheng Jiang
Metals 2022, 12(7), 1173; https://doi.org/10.3390/met12071173 - 10 Jul 2022
Cited by 7 | Viewed by 1841
Abstract
The continuous drive friction welding of 6061-T6 Al and copper was investigated herein. The results show that with an increase in rotation speed, the width of the welded zone was gradually increased with the generation of higher temperatures, and the grain size in [...] Read more.
The continuous drive friction welding of 6061-T6 Al and copper was investigated herein. The results show that with an increase in rotation speed, the width of the welded zone was gradually increased with the generation of higher temperatures, and the grain size in the dynamic recrystallization zone on the Al side first decreased and then increased due to the combined effect of heat and force. The microhardness on the bonding surface was significantly greater than that of the base materials due to the presence of intermetallic compounds, and there was a softening zone on both sides of the bonding surface, which was progressively more significant with an increase in the rotation speed. The ultimate tensile strength (UTS) of the welded joints first increased and then decreased with an increase in rotation speed. When the rotation speed was 1000 rpm, the UTS was at its peak value of 212 MPa, which reached 73.1% of the strength of the 6061-T6 Al base material. Full article
(This article belongs to the Special Issue Advances in Dissimilar Welding and Joining)
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22 pages, 7842 KiB  
Article
Comparative Microstructural, Mechanical and Corrosion Study between Dissimilar ATIG and Conventional TIG Weldments of 316L Stainless Steel and Mild Steel
by Kamel Touileb, Rachid Djoudjou, Abdeljlil Chihaoui Hedhibi, Abousoufiane Ouis, Abdallah Benselama, Albaijan Ibrahim, Hany S. Abdo and Ubair Abdus Samad
Metals 2022, 12(4), 635; https://doi.org/10.3390/met12040635 - 7 Apr 2022
Cited by 6 | Viewed by 2642
Abstract
Stainless steels and mild steels are widespread materials in several industries. The dissimilar welding of materials is a technique used to meet the needs of various industries. Mild steel and 316L austenitic stainless steel have different chemical compositions and thermal and mechanical properties. [...] Read more.
Stainless steels and mild steels are widespread materials in several industries. The dissimilar welding of materials is a technique used to meet the needs of various industries. Mild steel and 316L austenitic stainless steel have different chemical compositions and thermal and mechanical properties. Therefore, it would be interesting to develop a flux paste that would ensure the reliability and sustainability of welded structures made of dissimilar materials. In this work, pseudo-component fluxes were analyzed regarding the resulting weld aspects, microstructures, mechanical properties and corrosion resistance of dissimilar 316L austenitic stainless steel and mild steel welded joints. Using a mixing design available in Minitab 17 software, the obtained optimal pseudo-component flux was composed of 74% SiO2, 3% Fe2O3, 13% Cr2O3 and 10% NaF. During this investigation, the weld carried out using the optimal flux combination with the activated tungsten inert gas (ATIG) technique was evaluated and compared to another weld executed using the conventional tungsten inert gas (TIG) process. In conclusion, we observed that the optimal flux combination used in the ATIG weld had beneficial effects on the mechanical properties without degrading corrosion resistance when compared to the conventional TIG weld. Moreover, in the ATIG process, the weld depth was achieved in a single pass, while edge preparation or the addition of a filler metal was not required. Full article
(This article belongs to the Special Issue Advances in Dissimilar Welding and Joining)
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23 pages, 27205 KiB  
Article
Investigation of Applicability Flowdrill Technology for Joining Thin-Walled Metal Sheets
by Anna Guzanová, Erik Janoško, Dagmar Draganovská, Marek Vrabeľ, Miroslav Tomáš, Peter Horňak, Marek Vojtko and Nikita Veligotskyi
Metals 2022, 12(4), 540; https://doi.org/10.3390/met12040540 - 23 Mar 2022
Cited by 2 | Viewed by 2405
Abstract
The applicability of flowdrill technology to join steel and aluminum alloys is studied. When used to flowdrill two overlapped thin-walled materials, a joint is formed as a secondary effect. The quality of the resulting bushings forming the interference fit joint was investigated by [...] Read more.
The applicability of flowdrill technology to join steel and aluminum alloys is studied. When used to flowdrill two overlapped thin-walled materials, a joint is formed as a secondary effect. The quality of the resulting bushings forming the interference fit joint was investigated by metallography. The joints were formed using a combination of uncoated deep drawn steel, galvanized high-strength low alloy steel and aluminum alloy, in different positions in the joint. Subsequently, tensile shear testing of single joints was performed. The load-carrying capacity of the joints was also tested in combination with adhesive bonding. The combination of both technologies yields an increase in the dissipated energy of the joint at failure. The bonded connection provides a high maximum force at failure, the mechanical connection through bushings leads to an increase in the displacement value at failure, thereby increasing the area under the loading curve. The DC-Al joint showed the highest load-carrying capacity, up to 9 kN, as well as dissipative energy, up to 10.3 J. The joints were fractured by shearing of the inner bushing under tensile stress. The failure surfaces exhibited a typical ductile character with dimpled morphology. It was found that from the point of view of the load-carrying capacity of the joint, it is advisable to place a material with a higher melting temperature in the upper position in the joint. The combination of flowdrill technology with adhesive bonding results in a sealed joint with high load-bearing capacity, reduction in the risk of crevice and galvanic corrosion. Full article
(This article belongs to the Special Issue Advances in Dissimilar Welding and Joining)
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11 pages, 17874 KiB  
Article
Effect of Ni Addition on the Interfacial Strength of Al/Cu Dissimilar Welds Produced by Friction Stir Lap Welding
by Kota Kurabayashi, Shun Tokita and Yutaka S. Sato
Metals 2022, 12(3), 453; https://doi.org/10.3390/met12030453 - 7 Mar 2022
Cited by 8 | Viewed by 2969
Abstract
Al/Cu dissimilar joining is a key technology for reducing the weight and cost of electrical components. In this study, the dissimilar friction stir lap welding (FSLW) of a Ni-containing Al alloy to pure Cu was performed, and the effects of the addition of [...] Read more.
Al/Cu dissimilar joining is a key technology for reducing the weight and cost of electrical components. In this study, the dissimilar friction stir lap welding (FSLW) of a Ni-containing Al alloy to pure Cu was performed, and the effects of the addition of Ni on the weld strength and interfacial microstructure were examined. A thin intermetallic compound (IMC) layer was observed at the Al/Cu weld interface produced by FSLW. The addition of 3 at.% Ni effectively improved the weld strength, although the thickness of the IMC layer increased. The IMC layer formed at the Al/Cu interface without Ni comprised CuAl2 and Cu9Al4 from the pure Al side. In contrast, the IMC layer formed with 3 at.% Ni consisted of (Ni,Cu)Al, CuAl, and Cu9Al4 from the Al side. The addition of Ni eliminated the weak CuAl2/Cu9Al4 interface, thereby improving the weld strength. The results of this study suggest that the strength of the Al/Cu weld can be effectively improved by the thinning of the IMC layer caused by FSLW and the change in interfacial microstructure caused by Ni addition. Full article
(This article belongs to the Special Issue Advances in Dissimilar Welding and Joining)
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