Journal of Advanced Joining Processes最新文献

{"title":"Induction kinetic welding (IKW): An innovative one-shot solid-state technique for circular joints","authors":"Farzad Khodabakhshi,&nbsp;Mark Turezki,&nbsp;Adrian P. Gerlich","doi":"10.1016/j.jajp.2025.100353","DOIUrl":"10.1016/j.jajp.2025.100353","url":null,"abstract":"<div><div>In this research, an innovative solid-state joining technology has been introduced for butt-welding of circular sections with dissimilar tube and rod geometries, using induction kinetic welding (IKW). This process involves using induction to preheat material before bringing the pieces together, where rapid heating to below the base metal melting temperature followed quickly by applying axial force and shear rotation at the joint interface. A homogeneous weld microstructure consisting of refined grains and minimal heat affected zone (HAZ) is formed at the contact interface. The present work demonstrates this for a specific application involving a circular plug (with a diameter of ∼13 mm) and thin-walled tube (with a diameter of ∼13.4 mm and a wall thickness of ∼0.35 mm) both consisting of Zircaloy-4. Among the IKW processing parameters, the influence of preheating temperature and rotational shear displacement angle are the most critical inputs examined. The final joint stress distribution near the peak fracture load was modelled using finite element analysis (FEA). To this end, induction heating up to the temperature of ∼1400°C followed by a frictional shear-rotation angle of 60-degrees achieved formation of a sound solid-state weld with upset and removal of oxides from the contact interface. Afterward, the microstructural characteristics across the welding line and mechanical properties of the produced weldments were examined. A joining efficiency of 100% was achieved during the tensile fracture of the tube/plug weldment where fracture of the tube base metal has been achieved.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100353"},"PeriodicalIF":4.0,"publicationDate":"2025-10-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145219396","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":"Tailoring microstructure and interface integrity in Ti–316L dissimilar keyhole laser welding using controlled 3d magnetic field stimulation","authors":"Pinku Yadav ,&nbsp;Simone Gervasoni ,&nbsp;David Sargent ,&nbsp;Patrik Hoffmann ,&nbsp;Sergey Shevchik","doi":"10.1016/j.jajp.2025.100352","DOIUrl":"10.1016/j.jajp.2025.100352","url":null,"abstract":"<div><div>This study investigates the influence of externally applied magnetic fields—both alternating and rotating—on the microstructural evolution and interface integrity of laser-welded dissimilar joints between titanium and 316 L stainless steel. A fiber laser system was employed to perform keyhole-mode lap welding, with various magnetic field orientations introduced to actively manipulate the melt pool dynamics. Alternating fields (Bx, By, Bz) promoted grain refinement (reducing average grain size from 51.8 ± 4.1 µm to 36.2 ± 3.1 µm) and enhanced recrystallization (increasing the recrystallized fraction to ∼0.69), resulting in a finer microstructure and more discrete intermetallic compound (IMC) formation at the Ti–316 L interface. In contrast, rotating magnetic fields (Bxy, Byz, Bxz) encouraged coarser grain growth (increasing average grain size up to 80.1 ± 4.5 µm) and increased the presence of unrecrystallized regions (up to 0.484 fraction) due to stabilized melt flow and slower cooling rates. These conditions facilitated deeper interdiffusion and led to thicker, more continuous IMC layers, correlating with a peak microhardness of 576 ± 8 HV, potentially compromising joint integrity. The findings demonstrate that precise control of magnetic field configuration during laser processing offers a powerful tool to tailor interfacial microstructures and minimize brittle phase formation. This approach provides new opportunities to enhance the performance and reliability of dissimilar metal joints in critical structural applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100352"},"PeriodicalIF":4.0,"publicationDate":"2025-09-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145219387","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":"Multi-objective optimization of welding-induced residual stress and deflection in 6082-T6 aluminum alloy using validated thermo-mechanical modeling","authors":"Hamidreza Rohani Raftar ,&nbsp;Amir Khodabakhshi ,&nbsp;Tomi Suikkari ,&nbsp;Antti Ahola ,&nbsp;Tuomas Skriko","doi":"10.1016/j.jajp.2025.100351","DOIUrl":"10.1016/j.jajp.2025.100351","url":null,"abstract":"<div><div>Welding of aluminum alloys often introduces residual stress and deflection, compromising dimensional precision and structural performance. This study investigates the influence of key process parameters of gas metal arc welding on the thermo-mechanical response of 6082-T6 aluminum alloy butt joints. A numerical method was developed and validated using experimental measurements of temperature distribution (thermocouples), deflection (3D laser scanning), and residual stress(X-ray diffraction). A full-factorial design of experiments (DOE) was conducted, varying clamping configuration, plate thickness, welding sequence, and cooling conditions. Analysis of variance (ANOVA) quantified main and interaction effects. The study identified a trade-off between deflection and residual stress, which was addressed through multi-objective optimization using a desirability function approach. Deflection was reduced from 1.44 mm (measured experimentally) to 0.6 mm under optimized conditions, while the minimum residual stress was 171 MPa, representing a decrease of approximately 12%. The optimum condition corresponded to a partially restrained clamping configuration, a plate thickness of 4 mm, a continuous single pass welding sequence, and natural air cooling. Predictive models based on ensemble regression techniques were constructed using the 72 DOE-based FEM cases and validated with experimental measurements to estimate responses and rank influential parameters. The models achieved an R² values of 0.93 for deflection and an R² value of 0.94 for residual stress. Consistency between statistical and predictive analyses confirmed the dominant factors. The optimization framework offers a data-driven approach to improve welded structural integrity and highlights the potential of integrated simulation and data analysis in materials processing and design.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100351"},"PeriodicalIF":4.0,"publicationDate":"2025-09-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145219494","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":"Electron beam welding parameters for copper and dissimilar copper joints: Review, research gaps, and future challenges","authors":"Sathishkumar Duraisamy ,&nbsp;Ana Horovistiz ,&nbsp;Antonio Bastos ,&nbsp;Bernardo Mascate ,&nbsp;João M.S. Dias","doi":"10.1016/j.jajp.2025.100350","DOIUrl":"10.1016/j.jajp.2025.100350","url":null,"abstract":"<div><div>Copper welding presents significant challenges due to its high thermal conductivity and reflectivity, making traditional welding methods largely ineffective. Electron Beam Welding (EBW) offers a promising solution but requires precise parameter control to achieve optimal results. This study is a systematic review following a structured search of Scopus and Web of Science. After title–abstract–full text screening using predefined inclusion criteria (experimental EBW of copper or copper–dissimilar joints reporting process parameters and weld performance), 163 peer-reviewed articles were retained. For each study, the authors extracted process parameters (accelerating voltage, beam current, welding speed, focus/defocus, beam oscillation), material characteristics (alloy type, thickness, surface preparation), and outcomes (penetration, porosity, microstructure, mechanical properties). Reported statistical measures were consolidated to quantify the dominant influences of the parameters, and a SWOT analysis, along with a research gap analysis, was performed. Research indicates that vacuum-based EBW effectively overcomes copper welding difficulties while producing superior joint quality compared to other fusion processes. EBW achieves deep weld penetrations of up to 30 mm with minimal defects in copper, producing joint strengths of up to 264 MPa, equivalent to approximately 95% of the base material strength. Key welding parameters, including beam current, welding speed, focus position, and oscillation patterns, significantly influence weld quality, with beam current exerting the strongest effect on penetration depth. When joining copper to different materials, careful beam positioning and oscillation techniques successfully control unwanted compound formation while maintaining joint strength. Key findings establish that beam current accounts for 81% of the variance in weld quality control; strategic beam positioning with 0.4–0.5 mm offsets optimizes dissimilar joints, achieving strengths of 250 MPa; oscillation patterns reduce porosity by 30% while controlling intermetallic formation; and significant research gaps remain in copper tube joining applications for thermal management systems. This framework enables precision joining of high-performance copper systems for next-generation energy and electronics applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100350"},"PeriodicalIF":4.0,"publicationDate":"2025-09-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145108666","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":"Visualization of material flow in one-step double-acting FSW of AA1100: role of tracer type and morphology","authors":"Eko Prasetya Budiana,&nbsp;Anas Fikri Makarim,&nbsp;Heru Sukanto,&nbsp;Nurul Muhayat,&nbsp;Triyono","doi":"10.1016/j.jajp.2025.100349","DOIUrl":"10.1016/j.jajp.2025.100349","url":null,"abstract":"<div><div>Aluminum is widely used in industry due to its lightweight, high strength, and cost-effectiveness. However, conventional fusion welding of aluminum often results in porosity defects. One-step Double-Acting Friction Stir Welding (ODFSW) is an advancement of the FSW technique that enables simultaneous double-sided welding in a single pass at sub-melting temperatures, thereby overcoming porosity issues in fusion welding while also addressing challenges in single-sided FSW of thicker plates, such as incomplete penetration and root flaws. The quality of ODFSW joints is strongly influenced by the material flow behavior during welding. To investigate this flow, the Tracer Insert Technique was employed. This study examines the effect of tracer material type and form on the visibility of material flow in ODFSW of AA1100 aluminum with a 1 mm pin overlap. Three types of tracers were used: SiO₂ powder, AA6061 powder, and ER5356 wire. Results revealed that powder-form tracers, particularly AA6061, provided better visualization due to more uniform distribution and higher color contrast caused by the presence of Mg₂Si precipitates. Multi-Attribute Decision Making (MADM) evaluation identified AA6061 as the most effective tracer, exhibiting minimal defects. Material flow visualization indicated distinct patterns, including flow from the advancing side (AS) to the retreating side (RS), material accumulation at the weld exit, onion ring formation, microvoids at pin tips, and homogeneous mixing in the mid-plate region. Additionally, a funnel-shaped flow profile and material concentration at the mid-thickness zone were observed, attributed to the mechanical interaction between the upper and lower tools.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100349"},"PeriodicalIF":4.0,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145095122","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 process gas mixtures on weld material characteristics and bead geometry for wire-arc directed energy deposition","authors":"Michael Unger ,&nbsp;Sebastian Zehetner ,&nbsp;Thomas Klein ,&nbsp;Aurel Arnoldt ,&nbsp;Martin Schnall","doi":"10.1016/j.jajp.2025.100347","DOIUrl":"10.1016/j.jajp.2025.100347","url":null,"abstract":"<div><div>Shielding gases are used in welding technologies to prevent contamination and protect the metallic melt from disadvantageous effects that air could cause on the weld. While argon is mostly used for gas metal arc welding of aluminum, this paper investigates the use of mixtures with traces of different gases. Various properties of the weld seams are assessed: Effects on bead geometry, microstructure, defects, and mechanical characteristics of the resulting material. Investigations were performed for single welds as well as directed energy deposited wire-arc specimens. For this purpose, single bead on plate with CO₂, N₂, and O₂ in the mixture and wall geometry samples with N₂ and O₂ were manufactured and subsequently analyzed. Nitrogen in the gas mixture is reducing the bead and deposit width and decreasing the grain size compared to the reference sample. This grain size reduction is due to the formation of nitrides in the weld material acting as nucleants for new grains. Nitrides were identified by energy dispersive X-ray spectroscopy. Furthermore, nitrogen is reducing the number of pores but not significantly their volume fraction. A similar effect is reported for used amounts of O₂ on smaller scale. The characteristic mechanical strength values are comparable to reported data, but the elongation is reduced when nitrogen is present in the shielding gas mixture.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100347"},"PeriodicalIF":4.0,"publicationDate":"2025-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145044702","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 varying stiffness on the interfacial failure behavior of isotactic polypropylene and porous alumina studied via DPD simulation","authors":"Yoshitake Suganuma,&nbsp;James A. Elliott","doi":"10.1016/j.jajp.2025.100343","DOIUrl":"10.1016/j.jajp.2025.100343","url":null,"abstract":"<div><div>This work studies a polymer–metal oxide bonded interface consisting of isotactic polypropylene (iPP) and a porous surface, and examines the impact of the stiffness of the polymeric component on the tensile strength of the interface using the dissipative particle dynamics (DPD) method. Our calculations reveal that an increase in the stiffness of iPP component leads to an increased tensile strength on the porous alumina even in an interfacial failure. The tensile failure mode observed on the porous surface is caused by the slippage of iPP component along the pore walls. An iPP component with a higher Young’s modulus is more resistant to deformation during tensile tests, which makes it difficult for the interfacial stress to reach the critical strain for the slippage, and thus results in an increased tensile strength of the bonded interface.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100343"},"PeriodicalIF":4.0,"publicationDate":"2025-08-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144917747","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":"Continuous drive friction welding of commercial pure aluminum to copper: Metallographic and mechanical characterization of various cross-sections","authors":"Lucia Sauter ,&nbsp;Martin Werz ,&nbsp;Stefan Weihe","doi":"10.1016/j.jajp.2025.100342","DOIUrl":"10.1016/j.jajp.2025.100342","url":null,"abstract":"<div><div>An electrically and mechanically sound joint between aluminum and copper is essential in modern manufacturing, particularly in the field of e-mobility, where the demand for integrated, lightweight, and high-performance conductors continues to grow. However, because of the distinct metallurgical characteristics of these materials, their joining presents significant metallurgical and process-related challenges, including the formation of brittle intermetallic compounds (IMCs). Rotary friction welding (RFW) has emerged as a promising solid-state joining technique, enabling high-integrity dissimilar material bonds through the reduction of heat input and reducing IMC formation. This study investigates the metallurgical and mechanical properties of the aluminum-copper joints produced by RFW. A comprehensive microstructural analysis was conducted using scanning electron microscopy (SEM) on both fracture surfaces and cross-sectional samples. Energy-dispersive X-ray spectroscopy (EDX) was employed to examine the IMC phases at the weld interface, providing insights into their formation and distribution. To evaluate the mechanical performance of the joints, tensile tests were performed on specimens with varying diameters, allowing for an assessment of the weld integrity across different residual cross sections. This approach enabled the determination of whether a strong bond extends throughout the weld region. In addition, hardness measurements were conducted to further characterize the mechanical properties of the joint. The results provide a deeper understanding of the microstructural evolution and mechanical behavior of aluminum-copper RFW joints. The insights gained contribute to optimizing joint performance and the development of reliable bimetallic connections for industrial applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100342"},"PeriodicalIF":4.0,"publicationDate":"2025-08-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144895113","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":"Mechanistic insight into cooling-rate-driven bubble evolution and interfacial bonding strength in directly bonded Ti–PET materials","authors":"Katsuyoshi Kondoh ,&nbsp;Nodoka Nishimura ,&nbsp;Kazuki Shitara ,&nbsp;Shota Kariya ,&nbsp;Ke Chen ,&nbsp;Abdillah Sani Bin Mohd Najib ,&nbsp;Junko Umeda","doi":"10.1016/j.jajp.2025.100345","DOIUrl":"10.1016/j.jajp.2025.100345","url":null,"abstract":"<div><div>This study elucidates the mechanistic relationship between cooling rate and interfacial bubble evolution in direct bonding of commercially pure titanium (Ti) to polyethylene terephthalate (PET). Joints were fabricated via a thermal press-bonding process under two distinct cooling regimes—rapid and slow cooling—and the dynamic behavior of residual gas bubbles was analyzed through in-situ optical observation. Slow cooling was found to markedly reduce both the size and population density of interfacial bubbles, attributed to enhanced gas re-dissolution and diffusion within the softened PET matrix at elevated temperatures. Quantitative image analysis revealed that the bubble area fraction decreased by &gt;50 % under slow cooling conditions. Tensile shear testing showed that joints fabricated under slow cooling exhibited significantly higher bond strength—up to 1.5 times greater than those produced under rapid cooling—highlighting the deleterious role of residual bubbles as interfacial defects. Fractographic observations further indicated that slow cooling altered bubble morphology from network-like, dome-shaped structures to isolated, spherical forms, thereby increasing the effective bonded area and promoting interfacial adhesion. These findings provide critical insight into thermally driven interfacial phenomena in metal–polymer joining and underscore the importance of thermal management strategies for optimizing joint integrity.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100345"},"PeriodicalIF":4.0,"publicationDate":"2025-08-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144886020","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":"Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating","authors":"M.H. Khan ,&nbsp;S. Jabar ,&nbsp;T.I. Khan ,&nbsp;H.R. Kotadia ,&nbsp;P. Franciosa","doi":"10.1016/j.jajp.2025.100344","DOIUrl":"10.1016/j.jajp.2025.100344","url":null,"abstract":"<div><div>Laser beam welding is a critical joining method for wrought 6xxx series aluminium (Al) alloys; however, its broader adoption is hindered by the susceptibility to solidification cracking, which undermines weld integrity and restricts the production of high-quality joints. To mitigate cracking susceptibility, this study explores a novel approach involving the use of alumina (Al₂O₃) and titanium carbide (TiC) nanoparticles introduced into the fusion zone of laser welded AA6005 aluminium sheets via electrophoretic deposition (CuSO₄ bath, ∼40 nm nanoparticles, varying concentrations/times). Microstructural analysis revealed that the incorporation of both Al₂O₃ and TiC nanoparticles on AA6005 led to an overall 65% grain refinement, effectively preventing centreline cracking during welding. Lap shear testing demonstrated a significant improvement in joint strength, with a 10% increase for Al₂O₃ coated samples and a 13% increase for TiC coated welds compared to the uncoated material. Notably, TiC outperformed Al₂O₃ at higher concentrations, exhibiting more uniform dispersion with reduced agglomeration and porosity. In contrast, Al₂O₃ showed a tendency toward particle clustering and pore formation at elevated concentrations, which limited its strengthening efficiency. This highlights the potential of nanoparticle reinforcement for enhancing the reliability and performance of laser welded 6xxx aluminium alloys.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100344"},"PeriodicalIF":4.0,"publicationDate":"2025-08-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144886019","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}