Journal of Advanced Joining Processes最新文献

{"title":"The role of pressure in improving the properties of friction welded aluminum–copper dissimilar joints","authors":"Riyan Ariyansah ,&nbsp;Aditya Rio Prabowo ,&nbsp;Nurul Muhayat ,&nbsp;Bagus Anang Nugroho ,&nbsp;Triyono","doi":"10.1016/j.jajp.2025.100329","DOIUrl":"10.1016/j.jajp.2025.100329","url":null,"abstract":"<div><div>Rotary Friction Welding (RFW) is a solid-state joining technique well-suited for dissimilar metals such as aluminum and copper, despite challenges related to differences in electrochemical potential, thermal conductivity, and mechanical properties. While previous studies have explored the influence of process parameters on joint quality, limited attention has been given to the systematic optimization of axial pressure in relation to intermetallic compound (IMC) formation and mechanical performance. This study investigates the effect of varying axial pressures (20, 30, and 40 kg/cm²) on the microstructure and mechanical behavior of rotary friction-welded joints between 6061 aluminum and pure copper. The welding parameters, including rotational speed (1300 rpm), friction time (45 s), and pressure time (30 s), were held constant to isolate the effect of pressure. Macro and microstructural analyses, along with hardness and tensile testing, were conducted. The results show that axial pressure significantly influences the morphology and thickness of IMCs formed in the central weld zone (CWZ), thereby affecting joint strength. Notably, a friction pressure of 20 kg/cm² was found to be optimal, yielding the highest combination of hardness and tensile strength compared to other specimens, thus demonstrating a good balance between metallurgical bonding and mechanical performance. Compared to similar studies, this work demonstrates improved mechanical performance at a lower IMC thickness, highlighting the importance of pressure optimization in balancing metallurgical bonding with mechanical integrity. The novelty of this research lies in identifying the critical role of pressure in tailoring IMC development and optimizing joint strength for aluminum-copper dissimilar metal welding.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100329"},"PeriodicalIF":3.8,"publicationDate":"2025-07-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144605073","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":"Effect of bonding temperature on microstructure and mechanical properties of TLP-bonded Ti-6Al-4V/Inconel 718 joints using BNi2/Cu interlayer","authors":"Sepehr Pourmorad Kaleybar,&nbsp;Hamid Khorsand","doi":"10.1016/j.jajp.2025.100328","DOIUrl":"10.1016/j.jajp.2025.100328","url":null,"abstract":"<div><div>The joining of Ti-6Al-4 V to Inconel 718 is notable in industries. This research studied the effect of bonding temperatures (800, 850, 900, 950, and 1000 °C) on properties of Ti-6Al-4 V and Inconel 718 joints using BNi2/Cu interlayer in TLP bonding. The samples were analyzed for their microstructure and mechanical properties using a range of techniques: optical microscopy (OM), scanning electron microscope (SEM), X-ray diffraction (XRD), microhardness testing, shear strength evaluation, and high-temperature shear tests. Microstructural analysis indicated the formation of intermetallic compounds like Ti2Cu, Ti₂Ni, NiTi, and Ni₃Ti within the diffusion-affected zone (DAZ) and solidification zone (SZ) of the TLP-bonded samples. The results demonstrated that temperature had a profound impact on the microstructure of the TLP-bonded samples; specifically, the width of the solidification zone increased as the TLP temperature rose. Moreover, there was an optimal temperature for achieving superior mechanical properties. For instance, a shear strength of 399.75 MPa was achieved at 950 °C as the highest shear strength value. The findings also revealed that both lower (800 °C) and higher (1000 °C) bonding temperatures led to decreased shear strength due to the presence of porosities and cracks. The high-temperature testing showed suitable mechanical properties for elevated temperatures.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100328"},"PeriodicalIF":3.8,"publicationDate":"2025-07-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144597558","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":"Microstructure and mechanical properties of ethylene pyrolysis furnace tube weld joints after service","authors":"Jingfeng Guo ,&nbsp;Xiangping Guo ,&nbsp;Xiaoyu Li ,&nbsp;Guobing Hu ,&nbsp;Wenwen Liu","doi":"10.1016/j.jajp.2025.100327","DOIUrl":"10.1016/j.jajp.2025.100327","url":null,"abstract":"<div><div>The microstructure and mechanical properties of weld joints in ethylene pyrolysis furnace (Cr25Ni35NbM alloy and Cr35Ni45NbM alloy tube) after service were investigated in this work. The microstructure of the new weld joint and base metal of pyrolysis furnace tube vary widely, and the high temperature creep rupture time of the weld joint is only reached 50% of the base metal (1100°C, 16MPa). After high-temperature service, the microstructure of weld metal and base metal deteriorated and the high temperature creep strength decreased. Therefore, the microstructure of weld metal and base metal is tend to uniform, and the creep strength of weld joint and base metal reached the same level. After high-temperature aging, the primary carbides coarsen and secondary carbides precipitation results in a uniform microstructure and creep property of weld metal and base metal. The high temperature creep rupture time of weld joint reached 90% of base metal (1100°C, 16MPa). As the dispersion strengthening effect of the secondary carbide disappears, the creep strength of the weld joint no longer increases, but begins to decrease. Both high temperature service and elevated temperature aging result in the homogenization of the weld joint and base metal, and the high-temperature creep strength also reaches the same level.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100327"},"PeriodicalIF":3.8,"publicationDate":"2025-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144535840","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":"Friction stir welding tool trajectory error on the load capacity of EN AW-2024-T3 aluminum alloy joints","authors":"Magdalena Bucior ,&nbsp;Rafał Kluz ,&nbsp;Andrzej Kubit ,&nbsp;Hamed Aghajani Derazkola ,&nbsp;Enrico Cestino ,&nbsp;Ján Slota","doi":"10.1016/j.jajp.2025.100325","DOIUrl":"10.1016/j.jajp.2025.100325","url":null,"abstract":"<div><div>This study investigates the influence of tool trajectory deviations on the load capacity and material flow of friction stir welded (FSW) overlap joints made of EN AW-2024-T3 aluminum alloy. Given that robotic movement is inherently burdened with deviation errors from a theoretically linear trajectory, this study aimed to assess the impact of these deviations on weld quality. Since the FSW-capable robot has low stiffness, a HAAS TM1P milling machine was used to simulate the robot's motion, incorporating recorded deviation errors. The welding process of 1 mm thick sheets was first conducted under ideal rectilinear conditions, establishing optimal parameters: feed rate of 200 mm/min, tool rotational speed of 1517 rpm, and plunge depth of 1.46 mm. Subsequently, controlled trajectory errors with standard deviations ranging from 0.05 mm to 0.2 mm were introduced into the milling machine’s movement to replicate robotic deviation. The results indicate that trajectory deviations with a standard deviation of up to 0.1 mm do not significantly affect the load capacity (increase from 1.01% to 1.95%) but increase dispersion in mechanical performance (2.22% - 2.5%). SEM analysis revealed that when trajectory errors exceeded 0.15 mm, material folding and microcracks appeared, compromising weld integrity. Furthermore, multi-criteria optimization demonstrated that compensating for trajectory deviations is possible by adjusting welding parameters—specifically, reducing the feed rate to increase heat accumulation. This approach enables the production of welds with a minimal decrease in load capacity (1.55% lower than an ideal trajectory weld), mitigating the negative effects of robotic trajectory errors. The use of a feed rate of <em>x₂</em> = 296 mm/min and a rotational speed of <em>x₃</em> = 800 rpm allows for achieving a load capacity of the joints with an average value of 5.36 kN with a standard deviation of σ_F = 0.07 kN.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100325"},"PeriodicalIF":3.8,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144556740","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":"Influence of the pin diameter to spacing ratio in metal/composite joints joined via metallic pin structures","authors":"Julian Popp ,&nbsp;Jan Gavelek ,&nbsp;David Römisch ,&nbsp;Marion Merklein ,&nbsp;Dietmar Drummer","doi":"10.1016/j.jajp.2025.100326","DOIUrl":"10.1016/j.jajp.2025.100326","url":null,"abstract":"<div><div>Joining metal components with thermoplastic composites via the embedding of pin structures is a promising novel mechanical joining technology to create lightweight hybrid components. In the current state of the art, it is not understood which influence the pin size and pin arrangement in a multi pin array has on the mechanical performance of the created joints. In the scope of the present study different pin arrays have been used to create joints between stainless steel and unidirectionally reinforced thermoplastic composites. Thereby the pin density, which describes the fraction of the joint surface is occupied by pin structures, in the joint is kept constant and the pin size and pin arrangement has been varied. It shows that a higher number of smaller pins leads to better mechanical performance under both shear as well as normal testing load. Furthermore, an asymmetric pin arrangement, where one out of two pin rows is offset perpendicular to the fiber orientation, increased joint strength. The achieved shear strength of the samples reaches up to 10.8 MPa while the achieved normal strength is significantly lower at a maximum of 2.3 MPa.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100326"},"PeriodicalIF":3.8,"publicationDate":"2025-06-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144523795","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":"Effect of Mg-rich filler metal on weld zone properties in pulsed laser-welded ultra-fine grain AA6061: A Taguchi optimization study","authors":"S. Karami ,&nbsp;M.H. Siadati ,&nbsp;M. Yousefieh","doi":"10.1016/j.jajp.2025.100323","DOIUrl":"10.1016/j.jajp.2025.100323","url":null,"abstract":"<div><div>This study investigates the effects of filler metal with high magnesium (Mg) content at different heat inputs on microstructural evolution, strengthening mechanisms, and reduction of welding defects in pulsed laser welding (PLW) of ultra-fine-grained (UFG) AA6061 sheets. The dominant mechanism in UFG-welded AA6061 specimens, produced by accumulative roll bonding (ARB), was attributed to the grain boundary strengthening (GBS) effect due to grain size reduction and an increase in dislocation density. High heat input and remelting during PLW with AA5356 filler destroy the UFG structure, causing grain growth in the heat-affected zone (HAZ) and weld zone (WZ). It is shown that weld No. 7, with a heat input of 112 J/mm, and the use of high Mg filler metal contributed to the improvement of WZ strength due to increased fluidity, uniform distribution of this alloying element, and precipitation of Mg₂Si strengthening phase in the WZ. After welding under optimal conditions using a filler metal along with high Mg content, the strengthening mechanisms changed from the GBS effect and increased dislocation density to solid solution strengthening and precipitation of Mg₂Si as the strengthening phase. Scanning electron microscopy images show that laser welding using AA5356 filler metal eliminates the delamination effect and local necking, which are the leading causes of AA6061-UFGed failure. The failure in weld No. 7 indicates ductile fracture due to the heterogeneous distribution of dimples.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100323"},"PeriodicalIF":3.8,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144489755","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":"Enhancing the performance of double-flush riveted joints through hybridization with adhesive bonding","authors":"João M.B. Alpendre ,&nbsp;Pedro M.S. Rosado ,&nbsp;Rui F.V. Sampaio ,&nbsp;João P.M. Pragana ,&nbsp;Ivo M.F. Bragança ,&nbsp;Carlos M.A. Silva ,&nbsp;Paulo A.F. Martins","doi":"10.1016/j.jajp.2025.100324","DOIUrl":"10.1016/j.jajp.2025.100324","url":null,"abstract":"<div><div>This paper explores the potential to enhance the mechanical performance of joints created through a new joining-by-forming technique called hybrid double-flush riveting. To achieve this, adhesive bonding is used to form hybrid lap joints with superior mechanical properties. The study focuses on high-strength steel sheets and starts by identifying the appropriate surface conditions necessary for producing strong adhesive-bonded joints. A similar strategy is applied to construct double-flush riveted joints, focusing on the geometric variables involved in the process. Hybrid joints are then created by integrating adhesive bonding with double-flush riveting, with the second carried out before or after curing is completed. The experimental development is supported by finite element analysis conducted with an in-house computer program.</div><div>The mechanical performance of the hybrid joints is compared to that of purely adhesive-bonded and conventionally double-flush riveted joints through shear and peel destructive testing. Results demonstrate that hybrid joints ultimately provide greater joint strength for both solicitations. This allows showcasing the hybridization of double-flush riveting with adhesive bonding as an effective solution for applications where joint strength and continuity are essential.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100324"},"PeriodicalIF":3.8,"publicationDate":"2025-06-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144330512","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":"Thermo mechanical Finite Element Analysis of the plasma Wire Arc Additive Manufacturing process in DEFORM® 13","authors":"Marcel Czipin,&nbsp;Alexander Wenda,&nbsp;Karin Hartl,&nbsp;Emre Akalin,&nbsp;Martin Stockinger","doi":"10.1016/j.jajp.2025.100321","DOIUrl":"10.1016/j.jajp.2025.100321","url":null,"abstract":"<div><div>This study investigates the potential of Finite Element Analysis in DEFORM® to predict the thermal history, deformation, residual stress state and grain growth in the Wire Arc Additive Manufacturing processes of Ti–6Al–4V. The temperature dependent material model for Ti–6Al–4V was extended and adapted to improve the representation of contact boundary conditions within DEFORM®, focusing on Additive Manufacturing. A single layer quad-mesh approach was employed alongside dummy heat sources to simulate the process by accurate layer wise activation within the arc welding module. The model utilized a normalized double-ellipsoid heat source and introduced a power adaptation strategy to account for differences in volumetric deposition. The extracted thermal history showed very good agreement to corresponding thermocouple measurements. The accuracy of the resulting deformation state was validated using a 3D scan, while the predicted grain size distribution was compared against an as-built micrograph. The simulation showed good overall accuracy, though limitations were noted in the grain size model, which was inadequate in predicting the more complex texture of the mixed <span><math><mrow><mi>α</mi><mo>/</mo><mi>β</mi></mrow></math></span>-microstructure typical for Ti–6Al–4V. Seven heat treatment strategies were evaluated to address mechanical anisotropy. Solution annealing followed by water quenching and subsequent low temperature aging was found to be most effective.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100321"},"PeriodicalIF":3.8,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144307292","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":"Prediction of weld quality in laser welding of hardmetal and steel using high-speed imaging and machine learning methods","authors":"Mohammadhossein Norouzian ,&nbsp;Mahan Khakpour ,&nbsp;Marko Orosnjak ,&nbsp;Atal Anil Kumar ,&nbsp;Slawomir Kedziora","doi":"10.1016/j.jajp.2025.100318","DOIUrl":"10.1016/j.jajp.2025.100318","url":null,"abstract":"<div><div>Laser welding of steel and hardmetal presents significant challenges due to their differing material properties. Improper laser welding parameters can result in unstable joints, ultimately leading to reduced mechanical strength of the weld. Therefore, defining an optimal process window is critical to ensuring weld quality. In addition, a continuous process monitoring method like High-Speed Imaging (HSI) is essential in real industrial applications to maintain stability and detect potential defects. Understanding plume dynamics helps identify the most important features of weld quality, but it also provides deeper insight into operational parameters that discriminate different weld types. Analysis of individual image plume frames from HSI reveals distinct statistical features that are identified as unique to each welding condition. Performing systematic feature selection using plume morphology, spatter generation and weld quality, we achieved&gt;95 % leveraging Machine Learning (ML) classifiers. Particularly, Gradient Boosting Classifier (GBC), Linear Discriminant Analysis (LDA), Multinomial Logistic Regression (MNL-LR), Support Vector Machine (SVM), and Random Forest (RF), where the RF obtained &gt;99 % classification accuracy of weld quality. The RF was then used in performing Recursive Feature Elimination (RFE), and with the robustness analysis, we managed to reduce the number of features from forty-nine to nine features while maintaining satisfactory performance (Accuracy = 0.981, F1-score = 0.961, AUROC = 0.997). The position of the weld plume, plume eccentricity and plume width are the most essential features that lead to the improvement of node purity and classification accuracy.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100318"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144194641","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 “Exploring Wire-Arc Additive Manufactured Rivets for Joining Hybrid Electrical Busbars”","authors":"Pedro M.S. Rosado ,&nbsp;Rui F.V. Sampaio ,&nbsp;João P.M. Pragana ,&nbsp;Nuno M.S. Pereira ,&nbsp;Ivo M.F. Bragança ,&nbsp;Carlos M.A. Silva ,&nbsp;Paulo A.F. Martins","doi":"10.1016/j.jajp.2025.100291","DOIUrl":"10.1016/j.jajp.2025.100291","url":null,"abstract":"","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100291"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144261827","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}