Julian Popp , Jan Gavelek , David Römisch , Marion Merklein , Dietmar Drummer
{"title":"Influence of the pin diameter to spacing ratio in metal/composite joints joined via metallic pin structures","authors":"Julian Popp , Jan Gavelek , David Römisch , Marion Merklein , 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":"2025-12-01","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}
Laura de Lima e Silva , Nadège Ducommun , Laurent Jubin , Ronan Mainguy , Jérôme Esvan , Eric Andrieu , Christine Blanc
{"title":"Effect of the thermal oxide on the stress corrosion cracking susceptibility of stainless steels welds in chloride-containing media","authors":"Laura de Lima e Silva , Nadège Ducommun , Laurent Jubin , Ronan Mainguy , Jérôme Esvan , Eric Andrieu , Christine Blanc","doi":"10.1016/j.jajp.2025.100334","DOIUrl":"10.1016/j.jajp.2025.100334","url":null,"abstract":"<div><div>The stress corrosion cracking (SCC) susceptibility of a non-polished 316 L austenitic stainless steel (ASS) welded joint, <em>i.e</em>., covered by a thermal oxide film, was studied by carrying out uniaxial tensile tests in a 1 M NaCl solution (pH 4, 60 °C). Experiments were also performed on a polished weld, <em>i.e.</em>, covered by a native oxide film, for comparison. The thermal oxide film presented a bi-layer structure similar to that of the native oxide film, but the ratio Fe/Cr in the outer layer of the thermal oxide film was higher. Moreover, the thermal oxide film was thicker than the native oxide film, but it was more porous and showed a gradient in chemical composition and morphology as a function of the distance from the fusion line of the weld. The defective structure of the thermal oxide film was associated with a degradation in the corrosion behaviour of the non-polished weld, as well a change in the crack propagation mode during SCC tests, from intergranular to transgranular even though the cracks formed preferentially in the heat affected zone (HAZ) for both polished and non-polished samples. Furthermore, crack propagation was promoted, with cracks extending across multiple grains, in the HAZ of the non-polished sample near the fusion line, where the thermal oxide was more porous and richer in Fe compared to the HAZ far from the fusion line. The results therefore highlighted the major influence of the thermal oxide properties on the corrosion behaviour and SCC susceptibility of the 316 L weld.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100334"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144750347","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}
Noah E. El-Zathry , Rasheedat M. Mahamood , Wai Lok Woo , Sarah Green , Stephen Akinlabi , Naveen Loganathan , Vivek Patel
{"title":"Comparative evaluation of conventional friction stir welding and ultrasonic vibration-assisted friction stir welding techniques","authors":"Noah E. El-Zathry , Rasheedat M. Mahamood , Wai Lok Woo , Sarah Green , Stephen Akinlabi , Naveen Loganathan , Vivek Patel","doi":"10.1016/j.jajp.2025.100330","DOIUrl":"10.1016/j.jajp.2025.100330","url":null,"abstract":"<div><div>Enhancing joint strength in aluminium alloys remains a critical challenge for industrial applications. Friction stir welding (FSW) is a solid-state welding process that offers superior weld quality compared to fusion methods. However, further advancements are needed, particularly for high-performance alloys like third-generation Al-Li. To address this, ultrasonic vibration-assisted FSW (UVaFSW) has been explored as a potential enhancement. This study compares the mechanical and microstructural properties of AA2060-T8-E30 joints produced by FSW and UVaFSW. Key process parameters, including tool traverse speed and ultrasonic vibration amplitude (7.5 µm and 22.5 µm), were varied to assess their influence on weld quality. Mechanical performance was evaluated through tensile testing and Vickers microhardness, while microstructural characteristics were examined using optical microscopy and SEM. The results demonstrated that UVaFSW significantly improved material flow, reduced asymmetry in the thermo-mechanically affected zone (TMAZ), and refined the grain structure. Consequently, the ultimate tensile strength increased by 16.6 % and 31.8 % at 7.5 µm and 22.5 µm amplitudes, respectively, and elongation reached 11 %, nearly three times that of FSW. Furthermore, UVaFSW produced finer grains and more uniform precipitate distribution. Therefore, UVaFSW emerges as a promising technique for enhancing weld quality in advanced Al-Li alloys for demanding engineering applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100330"},"PeriodicalIF":3.8,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144656302","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}
Marcel Czipin, Alexander Wenda, Karin Hartl, Emre Akalin, Martin Stockinger
{"title":"Thermo mechanical Finite Element Analysis of the plasma Wire Arc Additive Manufacturing process in DEFORM® 13","authors":"Marcel Czipin, Alexander Wenda, Karin Hartl, Emre Akalin, 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":"2025-12-01","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":"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 , M.H. Siadati , 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 Mg<sub>2</sub>Si 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 Mg<sub>2</sub>Si 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":"2025-12-01","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}
Farzad Khodabakhshi, Mark Turezki, Adrian P. Gerlich
{"title":"Induction kinetic welding (IKW): An innovative one-shot solid-state technique for circular joints","authors":"Farzad Khodabakhshi, Mark Turezki, 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":"2025-12-01","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":"Continuous drive friction welding of commercial pure aluminum to copper: Metallographic and mechanical characterization of various cross-sections","authors":"Lucia Sauter , Martin Werz , 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":"2025-12-01","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}
Seonghyun Kim , Hyun-Uk Jun , Jooyong Cheon , Gyuheun Lee , Changwook Ji , Yang-Do Kim
{"title":"Effects of adjustable ring mode laser-beam control on microstructure and mechanical properties of AA6N01-T5 aluminum alloy in laser-arc hybrid welding","authors":"Seonghyun Kim , Hyun-Uk Jun , Jooyong Cheon , Gyuheun Lee , Changwook Ji , Yang-Do Kim","doi":"10.1016/j.jajp.2025.100358","DOIUrl":"10.1016/j.jajp.2025.100358","url":null,"abstract":"<div><div>This study evaluated the effects of beam control in adjustable ring mode laser-arc hybrid welding on the microstructure, porosity, and mechanical properties of a 5-mm-thick AA6N01-T5 Al alloy. Three laser-beam conditions—ring-beam hybrid welding (RBHW), center-beam hybrid welding (CBHW), and dual-beam hybrid welding (DBHW)—were compared under similar heat input conditions. The factors with the most significant influence on the mechanical properties in the welding of the AA6N01-T5 Al alloy are the porosity, grain size, and presence of strengthening precipitates. The weld porosity was quantified via high-resolution X-ray three-dimensional computed tomography, the grain structure was characterized via electron backscatter diffraction, the distribution and content of Mg—a key element in precipitation strengthening—were examined via electron probe microanalysis, and tensile and microhardness tests were performed in compliance with ASTM <span><span>standards</span><svg><path></path></svg></span>. RBHW achieved the lowest porosity (0.77 %) and the highest elongation (8.7 %) owing to the stable keyhole geometry and enhanced molten-pool convection. DBHW exhibited the smallest equiaxed grain size (179.43 μm) and the lowest Mg loss (0.89 wt%), resulting in the highest tensile (178.9 MPa) and yield (121.8 MPa) strengths. CBHW exhibited a combination of high porosity, coarse grains, and severe Mg loss, which degraded the mechanical performance of the weld. These findings clarify that the laser-beam energy distribution influences the molten-pool behavior, microstructure, and mechanical properties of the weld, thereby affecting the performance and reliability of high-strength Al alloy welds in lightweight manufacturing applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100358"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145519439","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}
Christian Frey , Mikail Kacar , Arda Hiz , Robert Gerlach , Willem Leterme , Simon Olschok
{"title":"Analyzing the utilization of high-voltage electric fields for laser material processing","authors":"Christian Frey , Mikail Kacar , Arda Hiz , Robert Gerlach , Willem Leterme , Simon Olschok","doi":"10.1016/j.jajp.2025.100341","DOIUrl":"10.1016/j.jajp.2025.100341","url":null,"abstract":"<div><div>Laser material processing has become an essential technique in industrial manufacturing in form of welding, drilling, cutting and structuring. However, process emissions such as the metal vapor plume pose a challenge, as they can impair the efficiency and precision of the laser process through reflection, absorption, and scattering. Conventional methods attempt to reduce the influence of the metal vapor plume by using shielding gases to remove the particles from the laser beam path. A novel alternative is the use of electric fields for targeted manipulation of the metal vapor to control the extinction effects. High voltage capacitors can precisely control the electric field which offers greater adaptability to a dynamic laser process. The following study investigates the utilization of high voltage capacitor configurations for generating electric fields to actively deflect metal vapor from the laser beam path during laser welding. The distribution of the electric field is analyzed using the finite element method (FEM) for the considered capacitor geometries. The weld seam geometry shows a distinct geometry depending on the selected capacitor arrangement, and the weld penetration depth decreases with the use of the electric field. The measurable trend remains preliminary, since it is assumed that the welding fume is held over the welding position by the electric field, which influences the result.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100341"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144829242","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}
João M.B. Alpendre , Pedro M.S. Rosado , Rui F.V. Sampaio , João P.M. Pragana , Ivo M.F. Bragança , Carlos M.A. Silva , Paulo A.F. Martins
{"title":"Enhancing the performance of double-flush riveted joints through hybridization with adhesive bonding","authors":"João M.B. Alpendre , Pedro M.S. Rosado , Rui F.V. Sampaio , João P.M. Pragana , Ivo M.F. Bragança , Carlos M.A. Silva , 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":"2025-12-01","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}