Journal of Advanced Joining Processes最新文献

{"title":"Corrigendum to “Surface cracks repair in AA6061-T6 aluminum alloys using friction stir processing” [Journal of Advanced Joining Processes (2025) /100340]","authors":"Fadi Al-Badour , Ahmad H. Bawagnih , Ahmed Ali , Rami K. Suleiman , Necar Merah","doi":"10.1016/j.jajp.2025.100346","DOIUrl":"10.1016/j.jajp.2025.100346","url":null,"abstract":"","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100346"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145733068","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":"Dissimilar TLP bonding of X-45/Hastelloy X superalloys using BNi-2 filler metal: Microstructural evolution and mechanical behaviors","authors":"A. Yarmou shamsabadi ,&nbsp;M. Farvizi ,&nbsp;L. Nikzad ,&nbsp;A. Malekan","doi":"10.1016/j.jajp.2025.100335","DOIUrl":"10.1016/j.jajp.2025.100335","url":null,"abstract":"<div><div>This article explores the dissimilar joining of two commonly utilized superalloys, X-45 and Hastelloy X (HX), through the Transient Liquid Phase (TLP) bonding technique using BNi-2 filler metal. The TLP process was performed at 1050 °C for varying durations (5–60 min). Microstructural analyses indicated that longer holding times at 1050 °C alongside the diffusion of Melting Point Depressant (MPD) elements into the base materials led to the completion of isothermal solidification and the elimination of the eutectic structure from the Athermally Solidified Zone (ASZ). The MPD elements exhibited varying diffusion rates across the joint's two sides. Increased diffusion of elements on the Hastelloy X side resulted in denser and more widespread precipitates than on the opposite side of the joint, although this region produced harder precipitates. To analyze the connection between microstructure and mechanical properties, a combination of microhardness and shear testing was utilized. Shear tests revealed two distinct types of fractures for joints formed over different durations: one type occurred when isothermal solidification was not completed, resulting in a cleavage fracture with low shear strength and weak bonding due to brittle eutectic compounds in the ASZ, while the other happened when isothermal solidification was complete, showing ductile fracture from the Diffusion Affected Zone (DAZ) that had the highest hardness following ASZ removal. The increased density of precipitates and broader precipitation zone on the HX side promote crack propagation along the boride-rich grain boundaries in this region, ultimately leading to the final fracture.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100335"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144757819","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":"Analysis of precipitation kinetics during refill friction stir spot welding and post-weld heat treatments in AA7050 using SAXS and numerical modeling","authors":"Susanne Henninger ,&nbsp;Rupesh Chafle ,&nbsp;Niklaas Becker ,&nbsp;Camila C. de Castro ,&nbsp;Benjamin Klusemann ,&nbsp;Martin Müller ,&nbsp;Peter Staron","doi":"10.1016/j.jajp.2025.100365","DOIUrl":"10.1016/j.jajp.2025.100365","url":null,"abstract":"<div><div>The impact of the refill friction stir spot welding process (refill FSSW) on precipitates in a high-strength AA7050-T7651 alloy is studied. Cross-sections of the welded samples are analyzed via small-angle X-ray scattering (SAXS), yielding 2D maps of spatial distributions of precipitate volume fraction and mean radius. The welding plunge times are varied during refill FSSW, leading to an increase in the width of the heat-affected zone (HAZ) with increase in energy input. The mean radius of precipitates increases above 25 nm at the edges of the stir zone (SZ) and thermo-mechanically affected zone (TMAZ). Dissolution and growth of <span><math><mi>η</mi></math></span>-precipitates in the HAZ are measured in-situ and are successfully modeled with the PanPrecipitation software. Moreover, the effect of various post-weld heat treatments (PWHT) on the precipitate distribution in the weld is analyzed. Reprecipitation in the HAZ is seen already after short aging times. After 20 min, the volume fraction increases all over the HAZ and nearly reaches the volume fraction of the base material. In the SZ/TMAZ, GP zones are formed through natural aging after welding and the PWHT lead to phase transformations and an increase in volume fraction and precipitate growth. Precipitates grow to a size of 2.5 nm after PWHT at 120 ℃ and 6.5 nm at 163 ℃. Thus, the formation of <span><math><mrow><msup><mrow><mi>η</mi></mrow><mrow><mo>′</mo></mrow></msup><mo>+</mo><mi>η</mi></mrow></math></span>-phase is expected after PWHT. Hardness measurements show that the PWHT lead to a hardness increase in the SZ and outer HAZ, but a minimum remains in the TMAZ/HAZ, where precipitates coarsened during welding. No significant changes in the weld zone features and the corresponding microstructure are observed between the as-welded and PWHT joints, indicating that the time–temperature conditions do not induce transformations such as grain growth and/or static recrystallization.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100365"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145681466","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of the pin diameter to spacing ratio in metal/composite joints joined via metallic pin structures","authors":"Julian Popp ,&nbsp;Jan Gavelek ,&nbsp;David Römisch ,&nbsp;Marion Merklein ,&nbsp;Dietmar Drummer","doi":"10.1016/j.jajp.2025.100326","DOIUrl":"10.1016/j.jajp.2025.100326","url":null,"abstract":"<div><div>Joining metal components with thermoplastic composites via the embedding of pin structures is a promising novel mechanical joining technology to create lightweight hybrid components. In the current state of the art, it is not understood which influence the pin size and pin arrangement in a multi pin array has on the mechanical performance of the created joints. In the scope of the present study different pin arrays have been used to create joints between stainless steel and unidirectionally reinforced thermoplastic composites. Thereby the pin density, which describes the fraction of the joint surface is occupied by pin structures, in the joint is kept constant and the pin size and pin arrangement has been varied. It shows that a higher number of smaller pins leads to better mechanical performance under both shear as well as normal testing load. Furthermore, an asymmetric pin arrangement, where one out of two pin rows is offset perpendicular to the fiber orientation, increased joint strength. The achieved shear strength of the samples reaches up to 10.8 MPa while the achieved normal strength is significantly lower at a maximum of 2.3 MPa.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100326"},"PeriodicalIF":3.8,"publicationDate":"2025-12-01","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}

{"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 ,&nbsp;Nadège Ducommun ,&nbsp;Laurent Jubin ,&nbsp;Ronan Mainguy ,&nbsp;Jérôme Esvan ,&nbsp;Eric Andrieu ,&nbsp;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}

{"title":"Comparative evaluation of conventional friction stir welding and ultrasonic vibration-assisted friction stir welding techniques","authors":"Noah E. El-Zathry ,&nbsp;Rasheedat M. Mahamood ,&nbsp;Wai Lok Woo ,&nbsp;Sarah Green ,&nbsp;Stephen Akinlabi ,&nbsp;Naveen Loganathan ,&nbsp;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}

{"title":"Thermo mechanical Finite Element Analysis of the plasma Wire Arc Additive Manufacturing process in DEFORM® 13","authors":"Marcel Czipin,&nbsp;Alexander Wenda,&nbsp;Karin Hartl,&nbsp;Emre Akalin,&nbsp;Martin Stockinger","doi":"10.1016/j.jajp.2025.100321","DOIUrl":"10.1016/j.jajp.2025.100321","url":null,"abstract":"<div><div>This study investigates the potential of Finite Element Analysis in DEFORM® to predict the thermal history, deformation, residual stress state and grain growth in the Wire Arc Additive Manufacturing processes of Ti–6Al–4V. The temperature dependent material model for Ti–6Al–4V was extended and adapted to improve the representation of contact boundary conditions within DEFORM®, focusing on Additive Manufacturing. A single layer quad-mesh approach was employed alongside dummy heat sources to simulate the process by accurate layer wise activation within the arc welding module. The model utilized a normalized double-ellipsoid heat source and introduced a power adaptation strategy to account for differences in volumetric deposition. The extracted thermal history showed very good agreement to corresponding thermocouple measurements. The accuracy of the resulting deformation state was validated using a 3D scan, while the predicted grain size distribution was compared against an as-built micrograph. The simulation showed good overall accuracy, though limitations were noted in the grain size model, which was inadequate in predicting the more complex texture of the mixed <span><math><mrow><mi>α</mi><mo>/</mo><mi>β</mi></mrow></math></span>-microstructure typical for Ti–6Al–4V. Seven heat treatment strategies were evaluated to address mechanical anisotropy. Solution annealing followed by water quenching and subsequent low temperature aging was found to be most effective.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100321"},"PeriodicalIF":3.8,"publicationDate":"2025-12-01","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 ,&nbsp;M.H. Siadati ,&nbsp;M. Yousefieh","doi":"10.1016/j.jajp.2025.100323","DOIUrl":"10.1016/j.jajp.2025.100323","url":null,"abstract":"<div><div>This study investigates the effects of filler metal with high magnesium (Mg) content at different heat inputs on microstructural evolution, strengthening mechanisms, and reduction of welding defects in pulsed laser welding (PLW) of ultra-fine-grained (UFG) AA6061 sheets. The dominant mechanism in UFG-welded AA6061 specimens, produced by accumulative roll bonding (ARB), was attributed to the grain boundary strengthening (GBS) effect due to grain size reduction and an increase in dislocation density. High heat input and remelting during PLW with AA5356 filler destroy the UFG structure, causing grain growth in the heat-affected zone (HAZ) and weld zone (WZ). It is shown that weld No. 7, with a heat input of 112 J/mm, and the use of high Mg filler metal contributed to the improvement of WZ strength due to increased fluidity, uniform distribution of this alloying element, and precipitation of Mg₂Si strengthening phase in the WZ. After welding under optimal conditions using a filler metal along with high Mg content, the strengthening mechanisms changed from the GBS effect and increased dislocation density to solid solution strengthening and precipitation of Mg₂Si as the strengthening phase. Scanning electron microscopy images show that laser welding using AA5356 filler metal eliminates the delamination effect and local necking, which are the leading causes of AA6061-UFGed failure. The failure in weld No. 7 indicates ductile fracture due to the heterogeneous distribution of dimples.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100323"},"PeriodicalIF":3.8,"publicationDate":"2025-12-01","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}

{"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":"2025-12-01","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 ,&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":"2025-12-01","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}