Journal of Advanced Joining Processes最新文献

{"title":"Mechanical properties and microstructure of the C70600 copper-nickel alloy and C46500 brass joint using brazing technique","authors":"Hesam Mehdikhani ,&nbsp;Amir Mostafapour ,&nbsp;Behzad Binesh","doi":"10.1016/j.jajp.2025.100294","DOIUrl":"10.1016/j.jajp.2025.100294","url":null,"abstract":"<div><div>Naval brass (C46500), due to the presence of tin in this alloy, it exhibits high resistance to atmospheric and aqueous corrosion. This type of brass is widely used in various industries, including marine applications, electrical components, etc. The C70600 copper-nickel alloy, due to the formation of a solid solution, maintains high ductility while increasing tensile strength. High resistance to seawater corrosion, attributed to significant amounts of manganese and iron, are among the key characteristics of this alloy. The joining of these alloys in marine applications are required. Considering the formation of solid solutions and intermetallic compounds and their impact on mechanical properties, controlling their amounts is crucial for achieving optimal results. Brazing is known as an effective method to join these base materials. Since temperature and time are two critical parameters in brazing, influencing the formation of precipitates, this study focuses on optimizing these conditions to achieve desirable microstructural and mechanical properties. The brazing process was performed under 16 different conditions including 650, 680, 710, and 740 °C for 1, 5, 15, and 30 mins. To study the microstructure of joints, and the related phase transformations in the joint region, optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) were used. Mechanical properties of the samples were evaluated through strength testing and micro hardness measurements. The results indicate that with increasing temperature and duration of the joining process, the width of the thermally solidified zone decreases due to the increased diffusion rate, while the width of the isothermal solidification zone increases. Moreover, increasing the brazing time promotes phase segregation. The highest strength, measured at 106.4 MPa, was achieved for the sample joined at 710 °C for 15 mins, with the fracture surface displaying a mixed ductile-brittle mode.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100294"},"PeriodicalIF":3.8,"publicationDate":"2025-02-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143387546","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Friction stir welding of dissimilar aluminum and copper alloys: A review of strategies for enhancing joint quality","authors":"Mohamed I.A. Habba ,&nbsp;Mohamed M.Z. Ahmed","doi":"10.1016/j.jajp.2025.100293","DOIUrl":"10.1016/j.jajp.2025.100293","url":null,"abstract":"<div><div>Friction stir welding (FSW) has emerged as a promising technique for joining dissimilar aluminum (Al) and copper (Cu) alloys, which are increasingly used in various industries owing to their unique properties. However, significant differences in the physical, thermal, and mechanical properties of Al and Cu pose challenges for achieving high-quality joints. This review comprehensively examines strategies for enhancing the joint quality of FSWed Al-Cu dissimilar alloys. The microstructural evolution and intermetallic compound (IMC) formation at the Al-Cu interface during FSW are discussed in detail. The effects of process parameters, such as tool rotation speed, traverse speed, and tool geometry, on the mechanical properties and fracture behavior of the joints were analyzed. Furthermore, various strategies for improving joint quality are reviewed, including process modification through optimized tool offsetting and material positioning, ultrasonic-assisted FSW, submerged FSW, stir zone modification using interlayers and reinforcement particles, external cooling and heating techniques, and joint design optimization. The effectiveness of each strategy in refining the microstructure, suppressing detrimental IMC formation, and enhancing the mechanical properties was evaluated based on the findings of previous studies. The research demonstrates that joint quality strongly depends on the precise control of process parameters and material positioning, with tool offsets of 1–2 mm toward the aluminum side consistently producing superior results. Modern assisted techniques have shown remarkable improvements in joint performance, with ultrasonic-assisted FSW and submerged FSW enhancing the tensile strength by up to 42 % through better control of the heat input and intermetallic compound formation. This review focuses on advanced strategies aimed at overcoming these challenges, including ultrasonic-assisted FSW, submerged FSW, and innovative interlayer techniques. Additionally, the review provides a comprehensive analysis of recent developments in process optimization, microstructural refinement, and mechanical property enhancement to achieve high-quality Al-Cu joints and offers guidance for selecting appropriate strategies to meet specific application requirements.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100293"},"PeriodicalIF":3.8,"publicationDate":"2025-02-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143420437","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The role of force and torque in friction stir welding: A detailed review","authors":"Mostafa Akbari ,&nbsp;Milad Esfandiar ,&nbsp;Amin Abdollahzadeh","doi":"10.1016/j.jajp.2025.100289","DOIUrl":"10.1016/j.jajp.2025.100289","url":null,"abstract":"<div><div>Friction Stir Welding (FSW) is a significant solid-state joining technique for metals and polymers, effectively addressing challenges posed by fusion welding. The application of FSW relies on the development of cost-effective, durable tools that consistently produce high-quality welds. The forces and torque generated during welding are critical to this process, which influence weld integrity, process efficiency, and tool longevity. This review explores methodologies for estimating these parameters—analytical, numerical, and experimental—and discusses measurement techniques, including direct and indirect methods. It also examines variations in forces across different FSW types, such as Conventional FSW, Bobbin Tool FSW, and Stationary Shoulder FSW, emphasizing the differences in their operational mechanics. Additionally, the review highlights how process parameters like tool shape, size, tilt angle, and welding speed can be optimized to enhance performance and investigates the use of force measurements for real-time weld monitoring and defect detection, contributing to the reliability of FSW in industrial applications. The results indicate that the use of force measurement for online monitoring of welding processes, particularly concerning welding defects and overall weld quality, has garnered significant attention in recent years. ​ A notable advancement in this field is the implementation of machine learning tools, which enhance the ability to predict potential weld defects and improve overall weld quality. This innovative approach not only streamlines the monitoring process but also contributes to the evolution of FSW technologies, ensuring higher standards of quality and safety in various applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100289"},"PeriodicalIF":3.8,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143350466","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of cooling rate on metallurgical and mechanical properties in continuous wave laser welding of hot-dip galvanised steel-to-aluminium sheets in a zero part-to-part gap lap joint configuration","authors":"A. Baghbani Barenji ,&nbsp;M.B. Russo ,&nbsp;S. Jabar ,&nbsp;H.R. Kotadia ,&nbsp;D. Ceglarek ,&nbsp;K.F. Ayarkwa ,&nbsp;J.R. Smith ,&nbsp;P. Franciosa","doi":"10.1016/j.jajp.2025.100290","DOIUrl":"10.1016/j.jajp.2025.100290","url":null,"abstract":"<div><div>Using a continuous wave (CW) laser with beam oscillation, this study elucidates the impact of passive and active cooling on welding hot-dip galvanised steel-to-aluminium sheets. The work investigates how cooling affects the formation of intermetallic compounds (IMCs) and the behaviour of Zn vapours, both of which are critical factors to the joint strength. IMCs are recognised as the most decisive factor in welding steel to aluminium, while Zn vapours significantly impact welding in a zero part-to-part gap overlap configuration. A 3D finite element method thermal model was employed to correlate the thermal cycles to the metallurgical and mechanical properties. The cooling rate without beam oscillation increased by 34% switching from passive to active cooling, while it was only 2.5% with oscillation present (2.5 mm lateral oscillation). Results revealed that active cooling influences Zn vapours and IMCs differently; faster cooling reduced total IMCs and Fe₂Al₅ phase and increased joint strength; however, it exacerbated spattering and weld discontinuity due to insufficient time for outgassing the Zn vapours from the molten pool. This adverse effect was more pronounced with beam oscillation due to larger molten pool. The experimental work also showed that despite beam oscillation does enlarge the connection area, the average shear stress was relatively lower compared to the case without oscillation, attributed to the increased thickness of the IMCs. Active cooling with water flow at 10 °C achieved 60% joint efficiency compared to parent aluminium, while beam oscillation reduced this to 54% but with half the strength variation. This highlights the complex, non-linear interplay between IMC formation, Zn vapour outgassing, and the dynamics of the molten pool.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100290"},"PeriodicalIF":3.8,"publicationDate":"2025-01-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143350465","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microstructural and defect characterization in single beads of the CrMnFeCoNi high-entropy alloy processed by the multi-beam laser directed energy deposition","authors":"Kholqillah Ardhian Ilman ,&nbsp;Yorihiro Yamashita ,&nbsp;Takahiro Kunimine","doi":"10.1016/j.jajp.2025.100288","DOIUrl":"10.1016/j.jajp.2025.100288","url":null,"abstract":"<div><div>This study investigates the microstructural characteristics and defect formation in single beads of the CrMnFeCoNi high-entropy alloy (HEA) processed by the multi-beam laser directed energy deposition (MBL-DED). The research aims to understand how the MBL-DED process can effectively control the bead formation with meltpool or without meltpool by leveraging the multi-beam laser focusing position in the MBL-DED system, and maintain the equiatomic balance of the HEA deposited on substrate surfaces by controlling the bead formation without meltpool and addressing potential defects. The formation of meltpool typically leads to mixing between the base material and the deposited HEA bead, altering the equiatomic balance and reducing the alloy's ability to stabilize the solid-solution phase. The multi-beam laser focusing position of the six laser beams of the MBL-DED system was adjusted to 0.5 mm above the substrate surface, with varying laser powers (80–160 W) and scanning speeds (10–40 mm/s). Hereafter, this laser geometry is called as overfocusing position, <em>∆f</em>, of 0.5 mm. This method shifted the process dynamics from a conventional meltpool formation to a thin reaction layer formation (no-meltpool formation). At a laser power of 140 W and a scanning speed of 30 mm/s, the absence of meltpool was observed. However, at 120 W, bead discontinuity increased with higher scanning speeds. Additionally, higher speeds and lower powers resulted in increased porosity, supported by partially melted and unmelted powder. Microstructural analysis revealed that increasing scanning speeds reduced grain size, transitioning from larger and uniform grains to finer and irregular grains. This research demonstrates the potential of the MBL-DED system in optimizing the HEA powder processing by controlling meltpool formation and mitigating defects, and in contributing to open up a new joining processing technology with less reaction layer through additive manufacturing.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100288"},"PeriodicalIF":3.8,"publicationDate":"2025-01-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133083","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Temperature influence on the repair of a hardfacing coating using laser metal deposition and assessment of the repair innocuity","authors":"Wilfried Pacquentin ,&nbsp;Pierre Wident ,&nbsp;Jérôme Varlet ,&nbsp;Thomas Cailloux ,&nbsp;Hicham Maskrot","doi":"10.1016/j.jajp.2025.100284","DOIUrl":"10.1016/j.jajp.2025.100284","url":null,"abstract":"<div><div>Additive manufacturing (AM) is a proven time- and cost-effective method for repairing parts locally damaged after e.g. repetitive friction wear or corrosion. Repairing a hardfacing coating using AM technologies presents however several simultaneous challenges arising from the complex geometry and a high probability of crack formation due to process-induced stress. We address the repair of a cobalt-based Stellite™ 6 hardfacing coating on an AISI 316L substrate performed using Laser Powder Directed Energy Deposition (LP-DED) and investigate the influence of key process features and parameters. We describe our process which successfully prevents crack formation both during and after the repair, highlighting the design of the preliminary part machining phase, induction heating of an extended part volume during the laser repair phase and the optimal scanning strategy. Local characterization using non-destructive testing, Vickers hardness measurements and microstructural examinations by scanning electron microscopy (SEM) show an excellent metallurgical quality of the repair and its interface with the original part. In addition, we introduce an innovative process qualification test assessing the repair quality and innocuity, which is based on the global response to induced cracks and probes the absence of crack attraction by the repair (ACAR<span><span>¹</span></span>). Here this ACAR test reveals a slight difference in mechanical behavior between the repair and the original coating which motivates further work to eventually make the repair imperceptible.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100284"},"PeriodicalIF":3.8,"publicationDate":"2025-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133080","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of microstructure and mechanical properties of austenitic steel bimetallic structures fabricated using wire arc direct energy deposition for remanufacturing applications","authors":"Rupendra Singh Tanwar,&nbsp;Suyog Jhavar","doi":"10.1016/j.jajp.2025.100287","DOIUrl":"10.1016/j.jajp.2025.100287","url":null,"abstract":"<div><div>In this work, bimetallic structures of two austenitic steels (SS316L and SS309) were fabricated using wire arc Direct Energy Deposition (DED). The fabrication process involved in the strategy of SS316L-SS309-SS316L on an SS316L substrate sequentially. Each material deposited 10 layers to one over another and forming two interfaces. Subsequently, the microstructure and mechanical properties, were evaluated in the deposited materials and at their interface. The microstructure predominantly consisted of the austenitic (γ) phase with a minimal amount of δ-ferrite phases in both stainless steels. The elemental distribution confirmed through EDS and verified by the Schaeffler diagram. SS309 exhibited a higher δ ferrite content compared to SS316L, and the interfaces showed a δ-ferrite content between the two base metals, the δ-ferrite mitigate the issue of hot cracking which occurred generally in the austenitic steels. The hardness ranged from 206 to 289 Vickers hardness (HV), with a considerable increase at the interface due to concentration of δ ferrite. The yield and ultimate tensile strengths were higher in the bimetallic samples tested in the build direction compared to the deposition direction with minimal variation indicating low anisotropy in mechanical properties. Tensile fracture results showed dimples, deep dimples, and microcracks, with failures occurring on the SS316L side. These findings demonstrate the effectiveness of the wire arc DED process in fabricating of bimetallic structure of SS316L-SS309 with improved strength.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100287"},"PeriodicalIF":3.8,"publicationDate":"2025-01-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133081","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Thermo-mechanical and material flow characteristics of tool sequencing dynamics in refill FSSW of thin alclad AA7075-T6 sheets: Numerical analysis using meshless smoothed-particle hydrodynamics method","authors":"Venkata Somi Reddy Janga,&nbsp;Mokhtar Awang,&nbsp;Nabihah Sallih,&nbsp;Tamiru Alemu Lemma","doi":"10.1016/j.jajp.2025.100285","DOIUrl":"10.1016/j.jajp.2025.100285","url":null,"abstract":"<div><div>This study is focused on improving the joint strength of AA7075-T6 specimens with aluminium cladding (alclad) joined through the refill friction stir spot welding (RFSSW) process. The bonding ligament weakens the RFSSW joint because the alclad layer is trapped between the specimens. This layer hinders material mixing during welding and creates a weak interface prone to crack initiation and propagation during external loading, affecting joint integrity. To overcome this problem, a novel tool sequencing variant of RFSSW, the pin plunging reinforced RFSSW (PPRSP-RFSSW), is proposed. A smoothed-particle hydrodynamics (SPH) formulation-based 3D thermo-mechanical model is developed to study the thermo-mechanical and material flow properties as it is possible to trace the field variables explicitly; it can manage significant material/elemental deformations and capture material mixing dynamically. The PPRSP-RFSSW is numerically analyzed and compared to existing sleeve plunging RFSSW (SP-RFSSW). The numerical model's accuracy was tested by comparing temperatures to experimental temperature data in published papers, and the results corresponded well. Comparisons are made between the SP-RFSSW and PPRSP-RFSSW concerning their heat distribution, plasticization, and material flow. Enhanced material mixing and plasticization were observed through PPRSP-RFSSW, and this tool sequencing is recommended for joining alclad AA7075-T6 specimens.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100285"},"PeriodicalIF":3.8,"publicationDate":"2025-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133079","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Pulsed GMAW-based WAAM–Influence of droplet detachment mode on the geometry and mechanical properties of 308 L stainless steel","authors":"R.F. Rezende ,&nbsp;A.R. Arias ,&nbsp;E.J. Lima II ,&nbsp;F.G.F. Coelho","doi":"10.1016/j.jajp.2025.100286","DOIUrl":"10.1016/j.jajp.2025.100286","url":null,"abstract":"<div><div>This study aimed to introduce pulsed gas metal arc welding (GMAW)-based wire arc additive manufacturing (WAAM) for the deposition of 308 L stainless steel. Then, the influence of the different droplet detachment modes on the geometric characteristics and mechanical properties of the deposited metal were analyzed. The detachment modes of one drop per multiple pulses (ODMP), one drop per pulse (ODPP), and multiple drops per pulse (MDPP) were analyzed. The experiments were performed by depositing preforms using 308 L stainless steel wire with a diameter of 1.0 mm on a 316 L stainless steel substrate. Characterization of the droplet detachment modes was performed using a high-speed camera and data acquisition system. Geometric analysis of the preforms was performed by photogrammetry. A greater heat input was observed in the ODMP mode. The MDPP and ODPP modes produced thinner preforms with a better surface finish. In addition, the MDPP mode generated better results in the manufactured preforms, with lower hardness and higher tensile strength. However, the ODMP mode led to relatively poorer results, with wider walls, greater surface waviness, and lower tensile strength. The results of this research are expected to provide technical and scientific support for the development of additive manufacturing by arc deposition, especially for stainless steel applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100286"},"PeriodicalIF":3.8,"publicationDate":"2025-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133073","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Neutron diffraction analysis of residual stress distribution in the lubricant-free TR-AFSD AA7075 repair coupled with SPH simulations","authors":"Ning Zhu ,&nbsp;Trevor Hickok ,&nbsp;Kirk A. Fraser ,&nbsp;Dunji Yu ,&nbsp;Yan Chen ,&nbsp;Ke An ,&nbsp;Luke N. Brewer ,&nbsp;Paul G. Allison ,&nbsp;J. Brian Jordon","doi":"10.1016/j.jajp.2025.100283","DOIUrl":"10.1016/j.jajp.2025.100283","url":null,"abstract":"<div><div>This work examines the residual stress in high-strength aluminum alloy repaired by lubricant-free additive friction stir deposition (AFSD) using the same aluminum alloy feedstock. Specifically, a milled groove in an AA7075-T651 substrate was repaired using the twin rod additive friction stir deposition (TR-AFSD) without using any graphite lubricant on the feedstock materials, which is required for conventional square feedstock AFSD. Residual stress distribution in the repaired substrate at different depths was quantified via neutron diffraction, where the distribution of longitudinal residual stress in the TR-AFSD repair was found comparable to materials subjected to other friction-based processes, with an M-shaped or bell-shaped distribution. The tensile longitudinal residual stress, with a peak of 171.3 MPa, spanned the center region around 36 mm, while compressive longitudinal residual stresses, ranging between -112.9 MPa and -12.3 MPa, were balanced outside the center at both the advancing side and retreating sides. The transverse and normal residual stresses were consistent across the repair, with smaller magnitudes between -52 MPa and 68.3 MPa. The non-destructive and high penetration depth nature of the neutron diffraction method enabled the calculation of von Mises stress by interpreting the three measured orthogonal residual stresses as the principal stresses. By normalizing the calculated von Mises stress to the microhardness, this quantified ratio indicates the influence of the embedded residual stresses relative to the material's strength. The higher normalized ratio observed at a deeper depth closer to the bottom of the repair, suggests that the magnitude of residual stresses is closer to the material's strength, indicating a higher potential for residual stress-induced failure at this location. We also calibrated the state-of-the-art smooth particle hydrodynamic (SPH) TR-AFSD process model to predict the von Mises stress distribution in the TR-AFSD AA7075 repair. The experimentally measured residual stress, coupled with the SPH simulation, could further help the research community to minimize the tensile region and alleviate substrate distortion in materials subjected to friction-based processes.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100283"},"PeriodicalIF":3.8,"publicationDate":"2025-01-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133071","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}