Journal of Advanced Joining Processes最新文献

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The Influence of temperature on the microstructure and properties of Cu/Al tube joints in magnetic pulse-assisted semi-solid brazing 温度对磁脉冲辅助半固态钎焊Cu/Al管接头组织和性能的影响
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-06-01 Epub Date: 2025-05-16 DOI: 10.1016/j.jajp.2025.100313
Zhenglei Rui , Shangyu Huang , Huajun Wang , Zhenghua Meng
{"title":"The Influence of temperature on the microstructure and properties of Cu/Al tube joints in magnetic pulse-assisted semi-solid brazing","authors":"Zhenglei Rui ,&nbsp;Shangyu Huang ,&nbsp;Huajun Wang ,&nbsp;Zhenghua Meng","doi":"10.1016/j.jajp.2025.100313","DOIUrl":"10.1016/j.jajp.2025.100313","url":null,"abstract":"<div><div>This study addresses the technical challenge of copper/aluminum (Cu/Al) tube joining through the innovative application of magnetic pulse-assisted semi-solid brazing (MPASSB) technology. Through an integrated approach combining finite element simulation with microstructural characterization, this study systematically investigates how brazing temperature (390–440 °C) influences the microstructure and mechanical properties of Cu/Al tube joints. Notably, a novel finite element method-smoothed particle hydrodynamics (FEM-SPH) coupling model has been developed. This model enables precise simulation of fluid-solid interactions between tubes and filler metal during the brazing process, providing fresh insights into oxide layer removal mechanisms. The research reveals that brazing temperature serves as the critical parameter governing the elemental diffusion and microstructural evolution in the joint. As the temperature increases from 390 °C to 440 °C, the viscosity coefficient of the filler metal decreases significantly from 41.6Pa·s to 1.798Pa·s, resulting in enhanced fluidity that promotes interfacial interactions between the tubes and filler metal and effectively removes surface oxide films, thus improving joint quality. However, excessive temperature intensifies the filler metal ejection, increasing the risk of filler metal deficiency at the top of the joint. Mechanical testing demonstrates that joints brazed at 440 °C achieve optimal shear strength of 81.1 MPa, with fracture occurring at the copper-side (Cu-side) interface between the Al<sub>4.2</sub>Cu<sub>3.2</sub>Zn<sub>0.7</sub> intermetallic phase and the diffusion layer. This work establishes fundamental theoretical guidance for optimizing MPASSB process parameters and facilitates the efficient joining of Cu/Al tubes.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100313"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144138835","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}
引用次数: 0
Enhancing microhardness and tensile strength of in-process cooled Al-7075-T651 FSAM laminates without compromising ductility through PWHT 在不影响PWHT延展性的前提下,提高Al-7075-T651 FSAM层压板的显微硬度和拉伸强度
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-06-01 Epub Date: 2025-04-15 DOI: 10.1016/j.jajp.2025.100304
Adeel Hassan , Khurram Altaf , Naveed Ahmed , Srinivasa Rao Pedapati , Roshan Vijay Marode
{"title":"Enhancing microhardness and tensile strength of in-process cooled Al-7075-T651 FSAM laminates without compromising ductility through PWHT","authors":"Adeel Hassan ,&nbsp;Khurram Altaf ,&nbsp;Naveed Ahmed ,&nbsp;Srinivasa Rao Pedapati ,&nbsp;Roshan Vijay Marode","doi":"10.1016/j.jajp.2025.100304","DOIUrl":"10.1016/j.jajp.2025.100304","url":null,"abstract":"<div><div>Friction Stir Additive Manufacturing (FSAM) is a promising technique for developing large, irregularly shaped components from non-fusionable aluminum alloys, such as Al-7075, while avoiding solidification defects. Studies on melting-based AM of Al-7075 have shown poor mechanical properties, whereas FSAM has demonstrated comparatively better mechanical properties, though with non-homogeneous properties. Furthermore, conventional post-welding heat treatment (PWHT) has been found to enhance microhardness and strength but significantly reduces ductility. This study addresses these challenges by employing in-process cooling FSAM and cyclic solution PWHT. Seven-layered Al-7075-T651 laminates were manufactured through FSAM, achieving a homogeneous microstructure and mechanical properties using the in-process cooling approach. The cyclic solution treatment resulted in a 38.3 % increase in hardness and a 17.17 % improvement in UTS compared to the as-welded state, without compromising ductility.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100304"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143847487","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}
引用次数: 0
Deep learning-driven active sheet positioning using linear actuators in laser beam butt welding of thin steel sheets 基于线性执行器的深度学习驱动薄板主动定位在薄板激光对焊中的应用
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-06-01 Epub Date: 2025-04-22 DOI: 10.1016/j.jajp.2025.100303
Dominik Walther , Leander Schmidt , Timo Räth , Klaus Schricker , Jean Pierre Bergmann , Kai-Uwe Sattler , Patrick Mäder
{"title":"Deep learning-driven active sheet positioning using linear actuators in laser beam butt welding of thin steel sheets","authors":"Dominik Walther ,&nbsp;Leander Schmidt ,&nbsp;Timo Räth ,&nbsp;Klaus Schricker ,&nbsp;Jean Pierre Bergmann ,&nbsp;Kai-Uwe Sattler ,&nbsp;Patrick Mäder","doi":"10.1016/j.jajp.2025.100303","DOIUrl":"10.1016/j.jajp.2025.100303","url":null,"abstract":"<div><div>Welding thin steel sheets in industrial applications is difficult because joint gaps occur during the process, which can lead to weld interruptions. Such welds are considered a reject and in order to avoid the weld to interrupt it is crucial to hinder the formation of joint gaps. Especially laser beam welding is affected by the emergence of gaps. Due to the narrow laser spot, product quality is highly dependent on the alignment and positioning of the sheets. This is typically done by clamping devices, which hold the workpieces in place. However, these clamps are suited for a specific workpiece geometry and require manual redesign every time the process changes. Adaptive clamping devices instead are designed to realize a time-dependent workpiece adjustment. Modeling the joint gap behavior to realize a controller for adaptive clamps can be difficult as the influence of heating, melting, and cooling on the joint gap formation is unknown and varies due to temperature dependent physical properties. Instead, the control parameters and actions can be derived using data-driven methods. In this paper, we present a novel data-driven approach how deep learning can be utilized to manipulate the sheet position during the weld with two actuators that apply force. A temporal convolution neural network (TCN) analyzes the change of the joint gap and predicts the required force to adapt the workpiece position. The developed method has been integrated into the welding process and improves the length of the average weld seam by 39.5% compared to welds without an active adjustment and 1.4% to welds that have been adapted with a constant force.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100303"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143879131","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}
引用次数: 0
Pulsed GMAW-based WAAM–Influence of droplet detachment mode on the geometry and mechanical properties of 308 L stainless steel 基于脉冲gmaw的waam -液滴分离方式对308l不锈钢几何和力学性能的影响
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-06-01 Epub Date: 2025-01-16 DOI: 10.1016/j.jajp.2025.100286
R.F. Rezende , A.R. Arias , E.J. Lima II , F.G.F. Coelho
{"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":"2025-06-01","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}
引用次数: 0
A new approach to the reasons for dependency of defects formation to the process parameters in laser powder bed fusion of IN625 on the IN738LC substrate 对IN625在IN738LC基板上激光粉末床熔接缺陷形成与工艺参数相关的原因进行了新的探讨
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-06-01 Epub Date: 2024-12-17 DOI: 10.1016/j.jajp.2024.100273
Amirhossein Riazi , Seyed Hossein Razavi , Alireza Khavandi , Mostafa Amirjan , Mohsen Ostad Shabani , Hossein Davarzani
{"title":"A new approach to the reasons for dependency of defects formation to the process parameters in laser powder bed fusion of IN625 on the IN738LC substrate","authors":"Amirhossein Riazi ,&nbsp;Seyed Hossein Razavi ,&nbsp;Alireza Khavandi ,&nbsp;Mostafa Amirjan ,&nbsp;Mohsen Ostad Shabani ,&nbsp;Hossein Davarzani","doi":"10.1016/j.jajp.2024.100273","DOIUrl":"10.1016/j.jajp.2024.100273","url":null,"abstract":"<div><div>Degradation is a common phenomenon in gas turbine components. Among additive manufacturing (AM) methods like direct laser deposition (DLD) and laser powder bed fusion (LPBF), DLD has been widely studied due to its ease in repair processes. However, LPBF offers higher dimensional accuracy, better surface quality, and reduced stress. This study employed LPBF of IN625 on an IN738 substrate for repair purposes. A wide range of process parameters (power at 100, 150, and 200 W and scan speeds between 100 mm/s to 2700 mm/s) was evaluated. The reasons behind process parameters' influence on defect formation, such as pores and cracks, were investigated, as these aspects have been less emphasized in prior studies. The relationship between process parameters, melt pool shape, pore formation, and changes in elemental concentration was explored. It was found that concentration peaks at the interface are the main factor in crack formation, enabling predictions of cracking behavior. Elements diffuse from rich to poor regions at the IN625/IN738 interface. At scan speeds ≤ 500 mm/s, increasing speed and power both increase elemental concentration at the interface, but speed promotes elemental accumulation behind the interface, while power enhances homogenization. The effect of process parameters on microhardness and cell size was also examined. It was determined that cracks do not form in softer nickel-based matrices where microhardness remains below the critical threshold of 256 HV.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100273"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133037","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}
引用次数: 0
Comparative analysis of structural and mechanical properties of duplex stainless steel (DSS) weldments prepared by flux core arc welding and shielded metal arch welding processes 双相不锈钢(DSS)焊条药芯电弧焊与保护金属拱焊结构与力学性能的对比分析
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-06-01 Epub Date: 2025-02-18 DOI: 10.1016/j.jajp.2025.100295
E. Ajenifuja , A.P.I. Popoola , O. Popoola
{"title":"Comparative analysis of structural and mechanical properties of duplex stainless steel (DSS) weldments prepared by flux core arc welding and shielded metal arch welding processes","authors":"E. Ajenifuja ,&nbsp;A.P.I. Popoola ,&nbsp;O. Popoola","doi":"10.1016/j.jajp.2025.100295","DOIUrl":"10.1016/j.jajp.2025.100295","url":null,"abstract":"<div><div>Duplex stainless steel (DSS) possesses wide range of useful metallographic and mechanical properties; hence the material has been used in different forms of application namely in chloride present environments such as desalination plants and cooling water services such as conventional and nuclear power stations. However, this material has its limitations as it's susceptible to cracking particularly stress corrosion cracking or pitting corrosion and can exhibit poor metallurgical properties such as microstructures and phase containing unbalanced proportions of ferrite and austenite. In this study, Flux Core Arc Welding (FCAW) is compared with Shielded Metal Arch Welding (SMAW) process, in terms of their effects on the structural and mechanical properties and performances of DSS weldments. Analysis of the microstructure and phases were carried out. Also, the tensile, microhardness, impact and fracture properties were determined with relevant techniques. The results indicated that SMAW and FCAW welding processes differentially influence the structural and mechanical properties of the DSS weldments, consisting of the part of base material, weld and the heat affected zone (HAZ). The weld prepared using the SMAW process exhibited superior hardness characteristics at 309 HV and achieved the highest impact energy absorption of 145.92 <em>J</em>. In contrast, the FCAW prepared weldment exhibited the highest tensile strength, reaching 282.30 kN maximum load.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100295"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143453796","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}
引用次数: 0
Advances in induction brazing of copper and dissimilar metals: Challenges and emerging trends 铜和异种金属感应钎焊的进展:挑战和新趋势
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-06-01 Epub Date: 2025-04-04 DOI: 10.1016/j.jajp.2025.100302
Eyuel A. Lemma , João M.S. Dias , António A. Bastos , Bernardo Mascate , Ana Horovistiz
{"title":"Advances in induction brazing of copper and dissimilar metals: Challenges and emerging trends","authors":"Eyuel A. Lemma ,&nbsp;João M.S. Dias ,&nbsp;António A. Bastos ,&nbsp;Bernardo Mascate ,&nbsp;Ana Horovistiz","doi":"10.1016/j.jajp.2025.100302","DOIUrl":"10.1016/j.jajp.2025.100302","url":null,"abstract":"<div><div>Induction brazing is emerging as a promising technique in current manufacturing processes, particularly noted for its effectiveness in the precise control of heat input, localized heating and rapid processing time. This joining technique is advantageous in industries such as heat pump and refrigeration manufacturing, which require precise and effective joining techniques, particularly for brazing copper and dissimilar metal pipes. Additionally, this technique is environmentally friendly, energy-efficient, cost-effective, and well-suited for automation.</div><div>However, studies have shown that induction brazing of copper and dissimilar metals presents several significant challenges, including thermal distortion-induced cracks due to unoptimized heat input and porosity defects stemming from inadequate filler metal penetration and suboptimal gap size between the joint, these issues can compromise joint integrity, as well as system durability and sustainability. Furthermore, the incompatible thermophysical properties of dissimilar materials and interconnectors pose substantial difficulties in achieving complete metallurgical bonding. The formation of undesirable microstructures, such as hard and brittle intermetallic compounds (IMCs), can further affect the structural, mechanical, and thermal properties of brazed joints.</div><div>This review systematically examines the effects of the most significant induction brazing process parameters on joint performance. Specifically, the effects of heat input, geometrical gap size between the joints, and composition of the filler material on the quality of brazed joints are discussed. Moreover, this review explores the induction brazing of copper with dissimilar metals, including copper with aluminum and copper with stainless steel. The impact of key process parameters on the joint quality of these materials was analyzed. Additionally, opportunities, challenges, and strategies to mitigate the challenges in induction brazing of copper and dissimilar metals are presented induction brazing are presented along with future research directions.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100302"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143807123","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}
引用次数: 0
Heat treatment optimisation of 18 % Ni maraging steel produced by DED-ARC for enhancing mechanical properties 为提高机械性能,对氩弧焊18% Ni马氏体时效钢进行热处理优化
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-06-01 Epub Date: 2025-05-16 DOI: 10.1016/j.jajp.2025.100312
Maja Lindič , Damjan Klobčar , Aleš Nagode , Nikolaj Mole , Borut Žužek , Tomaž Vuherer
{"title":"Heat treatment optimisation of 18 % Ni maraging steel produced by DED-ARC for enhancing mechanical properties","authors":"Maja Lindič ,&nbsp;Damjan Klobčar ,&nbsp;Aleš Nagode ,&nbsp;Nikolaj Mole ,&nbsp;Borut Žužek ,&nbsp;Tomaž Vuherer","doi":"10.1016/j.jajp.2025.100312","DOIUrl":"10.1016/j.jajp.2025.100312","url":null,"abstract":"<div><div>This article deals with the Directed Energy Deposition using Wire and Arc (DED-ARC) for maraging steel cladding. A technology for cladding using Gas Metal Arc Welding (GMAW) has been developed that enables the perfect deposition of maraging steel. The material characterisation was carried out in different material states: in the as-built, solution annealed and aged. The research included visual examinations, optical microscopy, Scanning Electron Microscopy / Energy-dispersive X-ray spectroscopy (SEM/EDS), fractography, hardness testing, tensile testing and impact toughness testing. The as-deposited state exhibited a microstructure with very long crystal grains and microsegregations orientated the direction of the heat sink, consisting of lath martensite. Consequently, a subsequent heat treatment is absolutely necessary in order to obtain a uniform fine-grained microstructure. Two different solution annealing processes were analysed, which allowed us to select the most suitable process for the first step of heat treatment followed by aging. A response surface methodology was used to optimise the aging conditions. The results show that additively manufactured maraging steel reaches a tensile strength of 1947 MPa, a hardness of 657 HV5 and a Charpy impact toughness of 11 J at peak aging condition, which is comparable to conventionally manufactured maraging steel.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100312"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144098349","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}
引用次数: 0
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 冷却速率对零间隙搭接结构下热镀锌钢铝板连续波激光焊接冶金性能和力学性能的影响
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-06-01 Epub Date: 2025-01-31 DOI: 10.1016/j.jajp.2025.100290
A. Baghbani Barenji , M.B. Russo , S. Jabar , H.R. Kotadia , D. Ceglarek , K.F. Ayarkwa , J.R. Smith , P. Franciosa
{"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 Fe<sub>2</sub>Al<sub>5</sub> 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":"2025-06-01","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}
引用次数: 0
Correlating geometry, microstructure and properties of High Strength Steel thin wall structures fabricated with WAAM WAAM制备高强钢薄壁结构的几何、微观结构和性能研究
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-06-01 Epub Date: 2025-02-15 DOI: 10.1016/j.jajp.2025.100292
Aravind Babu, Emiliano Trodini, José Luis Galán Argumedo, Ian M. Richardson, Marcel J.M. Hermans
{"title":"Correlating geometry, microstructure and properties of High Strength Steel thin wall structures fabricated with WAAM","authors":"Aravind Babu,&nbsp;Emiliano Trodini,&nbsp;José Luis Galán Argumedo,&nbsp;Ian M. Richardson,&nbsp;Marcel J.M. Hermans","doi":"10.1016/j.jajp.2025.100292","DOIUrl":"10.1016/j.jajp.2025.100292","url":null,"abstract":"<div><div>Wire arc additive manufacturing (WAAM) of high-strength steel (HSS) has gained significant attention for structural applications. Achieving precise control over the manufacturing process and understanding the relationship between process parameters and the resulting material characteristics is crucial for optimizing the performance of these steel walls to achieve tailored properties. The present study was performed to comprehend the influence of process parameters on the microstructure and properties of wire arc additively manufactured (WAAM) high-strength steel (HSS) thin-wall structures. Multi-layer thin walls of ER110S-G high-strength steel comprising 30 layers were deposited bidirectionally and were fabricated with different travel speeds and wire-feed rates. Geometrical analysis conducted on samples indicates that achieving minimal surface waviness for single-bead thin walls depends on adjusting wire feed rates and travel speeds. Specifically, lower wire feed rates are found to be more effective in minimizing waviness when dealing with single-bead thin walls (thickness <span><math><mo>&lt;</mo></math></span> 5 mm). Conversely, lower travel speeds are preferred for reducing surface irregularities in walls fabricated at high deposition rates for thicker single-bead walls (thickness <span><math><mo>&gt;</mo></math></span> 8 mm). Cooling rate analysis from midpoints of the 5th, 15th and 25th layers of each sample indicates high cooling rates for low heat input (HI=178 J/mm) samples even for the <span><math><mrow><mn>25</mn><mi>th</mi></mrow></math></span> layer. Microstructural characterization of the samples suggests an increase in acicular ferrite and martensite volume fraction with lower heat input. Additionally, microstructural quantification with EBSD reveals smaller grain sizes and higher Kernel average misorientation for low heat input deposits. Mechanical properties like hardness and tensile strength display an increasing trend with decreasing heat input while elongation to fracture is reduced under the same conditions. Furthermore, anisotropic behaviour is observed in tensile strength and elongation to fracture between building and deposition directions due to the presence of microstructural inhomogeneities.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100292"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143464927","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}
引用次数: 0
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