Journal of Advanced Joining Processes最新文献

{"title":"Bridgeability of large gaps in EN AW-6063 aluminium alloy by wire-based friction stir welding with a multi-pin tool","authors":"Stefan Donaubauer,&nbsp;Raphael Schmid,&nbsp;Stefan Weihe,&nbsp;Martin Werz","doi":"10.1016/j.jajp.2026.100379","DOIUrl":"10.1016/j.jajp.2026.100379","url":null,"abstract":"<div><div>Manufacturing deviations, assembly inaccuracies, and tolerances can create joint gaps that challenge conventional friction stir welding (FSW), which typically requires a tight fit-up to avoid issues such as tunnel defects, surface grooves, or insufficient bonding. In this study, a wire-based friction stir welding (W-FSW) approach using a stationary-shoulder multi-pin tool with an integrated extrusion-screw pin is presented to continuously feed EN AW-6063 aluminium filler wire into the joint. The filler wire is mechanically segmented, pre-plasticised within the tool, and intensively stirred into the substrate, enabling effective gap filling and a uniform material distribution in the weld zone. Gap widths of up to 4 mm, corresponding to 200% of the base material thickness, were successfully bridged, representing an extreme gap condition for thin-sheet aluminium joining, resulting in fully filled joints with a smooth and well-consolidated weld surface across all investigated gap widths. No weld undercuts or surface-related imperfections were observed. Electron backscatter diffraction (EBSD) analysis revealed a refined and stable microstructure. The weld nugget consistently exhibited grain sizes of 12–15 <span><math><mi>μ</mi></math></span>m, independent of gap width, while the thermo-mechanically affected zone and heat-affected zone remained nearly constant at 29–30 <span><math><mi>μ</mi></math></span>m (base material: 32 <span><math><mi>μ</mi></math></span>m). Tensile testing yielded an average ultimate tensile strength of 155 MPa with ductility comparable to reference joints, with fracture consistently occurring in the heat-affected zone, indicating stable mechanical performance despite the large joint gaps. Overall, the results demonstrate that multi-pin W-FSW provides a gap-tolerant and robust solid-state joining approach, significantly extending the practical application range of friction stir welding for EN AW-6063.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100379"},"PeriodicalIF":4.0,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146188380","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Quality assurance of clinched joints using explainable machine learning","authors":"Johannes Gerritzen ,&nbsp;Kunal Chopra ,&nbsp;Gregor Reschke ,&nbsp;Andreas Hornig ,&nbsp;Alexander Brosius ,&nbsp;Maik Gude","doi":"10.1016/j.jajp.2025.100368","DOIUrl":"10.1016/j.jajp.2025.100368","url":null,"abstract":"<div><div>Quality assurance (QA) of clinched joints is predominantly performed by destructive testing. Recently, non-destructive evaluation (NDE) methods received increasing attention as a potential alternative. However, the inherently indirect measurement of underlying effects poses a significant challenge to its broader application. To tackle this, two experimental data sets, containing a total of 43 potential process deviations and defects are established using transient dynamic analysis (TDA). On these, several machine learning (ML) models are trained to detect the underlying deviations. The best-in-class model is used to identify a frequency band at which a classification accuracy of 88.58% across all 43 classes is achieved. Further analysis of the most discriminative model features reveals the importance of measuring both excitation as well as specimen response. This lays the foundation for further research towards defect specific in-line measurements of mechanical joints, further improving joint reliability.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100368"},"PeriodicalIF":4.0,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145791060","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Factory simulation of adhesive bonding processes considering pot-life-induced waste","authors":"V Ginster ,&nbsp;A Weigert ,&nbsp;MK Heym ,&nbsp;CJA Beier ,&nbsp;A Schiebahn ,&nbsp;S Galka","doi":"10.1016/j.jajp.2026.100375","DOIUrl":"10.1016/j.jajp.2026.100375","url":null,"abstract":"<div><div>The simulation of production systems in the planning phase is an established tool for evaluating system performance under dynamic conditions (<span><span>Da Silva et al., 2018</span></span>). When planning a production system that includes time-critical processes such as adhesive bonding, exceeding time constraints (e.g., excessive lead times relative to the adhesive pot-life) can lead to product rejection and scrap. These risks should be analyzed by means of simulation, as it enables the consideration of stochastic effects such as random machine breakdowns, which significantly influence product lead times.</div><div>This study focuses on the production of adhesively bonded electrolyzer-cells. Due to the cell design, several handling and stacking operations must be carried out between adhesive application and final joining, so that immediate joining is not feasible and pot-life-induced scrap becomes a critical risk factor. We therefore conducted an exploratory investigation that combines experimental pot-life characterization with discrete-event simulation of a planned electrolyzer-cell production system.</div><div>A two-component epoxy adhesive was characterized using differential scanning calorimetry with kinetic analysis, rotational rheometry, and 90° peel tests on application-representative joints. Based on these tests, an application-specific pot-life was derived and implemented as a time-dependent quality criterion in the discrete-event simulation model. A full-factorial simulation study with varied buffer size and mean time to repair at a station availability of 98 % was carried out. The results demonstrated a pronounced trade-off between throughput and pot-life-induced waste and identified a buffer capacity of one and short repair times as the most favorable configuration. Extending pot-life due to different processing temperatures substantially reduced scrap, highlighting the benefit of integrating curing kinetics and dynamic simulation in early-stage production system design for time-critical adhesive processes.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100375"},"PeriodicalIF":4.0,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145977393","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Mechanical testing of battery electrodes by pull-off and peel tests: A comparative study","authors":"H. Gruhn ,&nbsp;A. Rajic ,&nbsp;T. Krueger ,&nbsp;M. Mund ,&nbsp;M.W. Kandula","doi":"10.1016/j.jajp.2026.100378","DOIUrl":"10.1016/j.jajp.2026.100378","url":null,"abstract":"<div><div>In battery cell production, electrodes are manufactured by coating current collectors with an active‐material slurry. Upon drying, this forms a porous composite of active material, conductive additives, and binder. The mechanical integrity of this coating is critical for electrode quality and subsequent processability. To assess these properties, pull-off tests and peel tests are commonly employed. While frequently categorized as “adhesion tests,” this label can be misleading; the fracture surfaces in these porous composites are rarely purely adhesive, yet a critical analysis of the specific fracture patterns is often neglected.</div><div>This study evaluates and compares the qualitative fracture patterns and quantitative results of both methods. To assess the sensitivity of each test, electrode properties were systematically varied by altering electrode thickness, binder type, and applying different calendering parameters. Results indicate that pull-off tests yield significant scatter due to undefined, multiaxial stress distributions, leading to inhomogeneous fracture patterns. In contrast, peel tests demonstrate minimal scatter with well‐defined crack propagation in a single plane, allowing for the detection of slight deviations in mechanical properties. Notably, the two methods reveal diverging trends regarding the impact of electrode thickness and calendering. Consequently, data from these methods are strictly incommensurable due to their fundamental mechanical difference.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100378"},"PeriodicalIF":4.0,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146188479","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Corrigendum to ‘The effect of heat input on the residual stress distribution in gas-metal arc welding of carbon steel: Simulation and experimental methods’ [Journal of Advanced Joining Processes 12 (2025) 100333]","authors":"Amir Dadkhah ,&nbsp;Mahmoud Sarkari Khorrami ,&nbsp;Seyed Farshid Kashani-Bozorg ,&nbsp;Reza Miresmaeili","doi":"10.1016/j.jajp.2025.100370","DOIUrl":"10.1016/j.jajp.2025.100370","url":null,"abstract":"","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100370"},"PeriodicalIF":4.0,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148184241","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Joining interfaces of laser-patterned AA5052–CFRP using TiO₂/SiO₂/MWCNT/PVCs nanocomposites synthesized via sol gel methods for superhydrophilic performance: DIC, experimental, and systematic insights","authors":"Ferry Setiawan ,&nbsp;Dicke Joshua ,&nbsp;Zufar Alfarros ,&nbsp;Gesang Nugroho ,&nbsp;Muhammad Akhsin Muflikhun","doi":"10.1016/j.jajp.2026.100406","DOIUrl":"10.1016/j.jajp.2026.100406","url":null,"abstract":"<div><div>Weak interfacial bonding remains a major limitation in developing hybrid structures for advanced mechanical and aerospace applications. This study integrates a systematic literature review with a comprehensive experimental investigation to evaluate the synergistic effects of laser-patterned superhydrophilic surfaces and TiO₂/SiO₂/MWCNT/PVCs nano multi-material reinforcement on interfacial bonding strength. From 263 reviewed papers (1996–2025), laser surface texturing (LST) and nanofiller addition emerged as dominant approaches to enhance adhesion in metal–composite systems. Experimentally, AA5052 aluminum substrates were modified using LST combined with etching–oxidation, forming circular micro-patterns that yielded superhydrophilic surfaces (Ra = 13.84 µm, contact angle = 0°, absorption time = 0.05 s). Hybrid joints were fabricated as Single Lap Joint (SLJ) through the Vacuum-Assisted Resin Infusion (VARI) one-step co-curing process, integrating six layers of carbon fiber reinforced polymer with epoxy resin containing 0–2.0 wt.% TiO₂/SiO₂/MWCNT/PVCs nano multi-materials synthesized via the sol–gel route from recycled solar-cell waste. Mechanical performance was evaluated by shear testing and Digital Image Correlation (DIC), while SEM–EDS, FTIR, and DSC confirmed morphological and chemical improvements. The optimal 1.5 wt.% reinforcement achieved a maximum shear strength of 19.5 MPa—an 11.3-fold enhancement— demonstrating a sustainable and cost-effective strategy for high-strength AA5052–CFRP hybrid bonding.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100406"},"PeriodicalIF":4.0,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148184235","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Use of expandable graphite as debonding on demand technology between glass fibre reinforced polyamide 6 and aluminium","authors":"Abdelghani Laachachi ,&nbsp;Oussema Kachouri ,&nbsp;Julian Berndt ,&nbsp;Gregor Zucker ,&nbsp;Camilo Zopp ,&nbsp;Jens Bartelt ,&nbsp;Ahmed Makradi","doi":"10.1016/j.jajp.2025.100369","DOIUrl":"10.1016/j.jajp.2025.100369","url":null,"abstract":"<div><div>A heat triggered debonding-on-demand thermoset-based adhesive is developed to join the glass fiber reinforced thermoplastic polyamide-6 to aluminium alloy sheet. The hybrid composite interface debonding mechanism is heat triggered at the end-of-life of the hybrid composite toward recycling of its components. The debonding-on-demand adhesive joint consist of an ARALDITE® brittle thermoset variant functionalized with 10% Expandable Graphite. TGA analysis and shear lab test are conducted to evaluate the effect of the Expandable Graphite on the degradation and mechanical performances of the ARALDITE® resin. Once validated the developed debonding-on-demand solution is up-scaled to a U-shape part made on inverse hybrid laminates.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100369"},"PeriodicalIF":4.0,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145925884","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Laser-modified wire arc cladding","authors":"Hana Šebestová ,&nbsp;Jan Novotný ,&nbsp;Jan Štěpán ,&nbsp;Ondřej Ambrož ,&nbsp;Zdeněk Joska ,&nbsp;Jan Gross ,&nbsp;Libor Mrňa","doi":"10.1016/j.jajp.2026.100381","DOIUrl":"10.1016/j.jajp.2026.100381","url":null,"abstract":"<div><div>The deposition of functional cladding layers is a widely adopted technique to enhance the surface performance of engineering components without compromising their bulk material properties. Among the available techniques, wire arc cladding offers high productivity and is particularly effective for depositing relatively thick coatings. Thanks to its high hardness and reasonable toughness, Stellite 6 alloy is well-suited for wear-resistant claddings; however, its application through various welding processes is often accompanied by cracking. In this study, we propose and experimentally investigate a novel approach to wire arc cladding of this Co-based alloy that integrates localized in-situ heat treatment using a defocused oscillating laser beam. The laser-assisted process produced continuous and more uniform cladding layers. Compared to conventional wire arc cladding, the cooling rate decreased by 40 %, resulting in improved bead homogenization and fewer welding voids, while maintaining comparable microhardness after two passes. Enhanced bead fusion, facilitated by the laser, enabled very high deposition speed without compromising the structural integrity of the claddings.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100381"},"PeriodicalIF":4.0,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146188381","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of microstructural and mechanical properties of dissimilar WC–8 %Co/AISI 1006 steel joints brazed using tube, induction, and infrared furnaces","authors":"Amin Shafinejad Bejandi,&nbsp;Hamid Khorsand,&nbsp;Mehdi Moslemi,&nbsp;Ali Ostad Akbarian Azar","doi":"10.1016/j.jajp.2025.100357","DOIUrl":"10.1016/j.jajp.2025.100357","url":null,"abstract":"<div><div>Integrating tungsten carbide (WC–8Co) with steel is a pivotal aspect of cutting tool manufacturing, as monolithic carbide tools are inherently brittle and cannot be fabricated as a single component. To enhance toughness and resistance to dynamic stresses, WC is brazed to steels with greater ductility. Given WC's high melting temperature, conventional welding methods are ineffective, making brazing one of the most suitable techniques for joining dissimilar materials. This study aimed to optimize the brazing process to minimize the loss of WC hardness, as a reduction in hardness compromises tool efficiency and lifespan. In this research, WC–8Co was brazed to AISI 1006 steel using a silver-based filler (BAg22) through tube, induction, and infrared furnaces at temperatures of 800 °C, 850 °C, and 900 °C under vacuum conditions, with induction powers set at 10 and 15 kW. The microstructural and mechanical properties were assessed using scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), microhardness testing, and shear testing. The initial hardness of WC was measured at 2202 HV, with decreases of 1.8%, 10%, and 22% observed for the induction, infrared, and tube furnaces, respectively. The shear strength was highest for the induction furnace (294 MPa), followed by the infrared furnace (268 MPa) and the tube furnace (202 MPa). OM/SEM/EDS analyses revealed a silver- and copper-rich eutectic structure, while elevated temperatures enhanced filler wettability and diffusion, resulting in uniform, defect-free joints. These findings yield quantitative insights for optimizing the brazing of WC–steel joints, facilitating the manufacturing of high-performance cutting tools.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100357"},"PeriodicalIF":4.0,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145738199","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Next-generation aircraft structures enabled by tailored friction stir welding and laser welding","authors":"Markus Wagner ,&nbsp;Andreas Grimm ,&nbsp;Rishabh Rajesh Rao ,&nbsp;Axel Jahn ,&nbsp;Dirk Dittrich ,&nbsp;Philipp Mohlau ,&nbsp;Andreas Wetzig ,&nbsp;Kai Fortkamp","doi":"10.1016/j.jajp.2026.100407","DOIUrl":"10.1016/j.jajp.2026.100407","url":null,"abstract":"<div><div>Structural components of aircraft fuselages, such as frames and stringers, are predominantly manufactured from milled high-strength aluminum profiles. In the milling process of frame structures, particularly at in the area around emergency exit doors, approximately 98% of the raw material is removed. This results in high material and production costs, along with significant energy consumption and a poor CO₂ footprint. Despite these drawbacks, milling remains the standard manufacturing method, as the high-strength aluminum alloys commonly used (e.g. EN AW-7075 T651) are prone to hot cracking and therefore not suitable for conventional welding.</div><div>This study presents and evaluates weldable fuselage stiffening structures designed to reduce material usage and component mass (with weight savings of up to 4%), while enhancing mechanical performance (achieving stiffness increases of up to 11%) compared to conventionally milled components. Weldability is achieved through structurally optimized joint geometries, tailored friction stir welding (FSW) processes and specialized clamping devices. Additionally, innovative laser welding techniques employing dynamic beam shaping (DBS) are introduced. The proposed solutions for frames and stringers are based on single-sheet designs with load-adapted thickness distributions and weld configurations. Friction Stir Additive Manufacturing (FSAM) is employed to integrate fuselage doublers into highly stressed areas.</div><div>This work opens new perspectives for resource-efficient structural concepts and represents a key step toward weldable fuselage architectures. Initial prototype simulation and testing have demonstrated promising structural integrity. The proposed solutions offer strong potential for scalable and sustainable production in aerospace as well as the automotive and energy sectors.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"13 ","pages":"Article 100407"},"PeriodicalIF":4.0,"publicationDate":"2026-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148184240","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}