Journal of Advanced Joining Processes最新文献

{"title":"Effects of triflute pin geometry on defect formation and material flow in FSW using CEL approach","authors":"Mostafa Akbari ,&nbsp;Parviz Asadi","doi":"10.1016/j.jajp.2024.100259","DOIUrl":"10.1016/j.jajp.2024.100259","url":null,"abstract":"<div><div>Complicated tool pin designs in Friction Stir Welding (FSW) need to be considered in terms of material flow and defect formation. This study investigates the effects of the triflute tool's geometrical parameters on temperature, strain, void formation, and material mixing using a numerical method. The numerical model employs a coupled Eulerian-Lagrangian (CEL) formulation and successfully predicts void formation and material mixing during friction stir welding (FSW). Four tool pin designs are considered for material flow, including one cylindrical pin and three triflute pins with flute radii of 1 mm, 1.5 mm, and 2 mm. The findings indicate that the stir zone is divided into shoulder-driven and pin-driven zones, each exhibiting distinct material flow patterns. In the shoulder-driven zone, material flow toward the advancing side is dominant, while in the pin-driven zone, it flows toward the retreating side. Flutes on the FSW pin tool increase the sweeping rate, strain, and material movement in the stir zone. However, flutes with a larger radius sweep a greater amount of material and thus require more softened material to facilitate movement. Therefore, for defect-free joint formation, a higher rotational speed of the tool will be required, which may adversely affect tool lifespan and joint mechanical properties. The effectiveness of flutes with a smaller radius of 1 mm is significantly greater than that of those with a larger radius (1.5 or 2 mm) in enhancing material flow and achieving defect-free welding.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100259"},"PeriodicalIF":3.8,"publicationDate":"2024-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434381","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effects of water cooling of friction stir welding of magnesium alloy stiffness joint","authors":"Hamed Aghajani Derazkola ,&nbsp;Andrzej Kubit","doi":"10.1016/j.jajp.2024.100257","DOIUrl":"10.1016/j.jajp.2024.100257","url":null,"abstract":"<div><div>This study presents a comparative analysis of friction stir welding (FSW) and underwater friction stir welding (UFSW) of AZ31 magnesium alloy in T-configuration, emphasizing the effects on heat distribution, material properties, and mechanical performance. Simulation results revealed a more uniform heat distribution in both welding techniques, with the hottest area on the advancing side. The maximum temperatures recorded at the shoulder-workpiece contact were 404 °C for FSW and 349 °C for UFSW, a 13.6 % reduction in UFSW. Material velocity at the trailing edge was 63 mm/s for FSW and 42 mm/s for UFSW, showing a 34 % decrease due to lower heat generation in UFSW. Strain rates were 450 s⁻¹ for FSW and 420 s⁻¹ for UFSW. Grain size in the stir zone was 26 micrometers for FSW and 21 micrometers for UFSW, a 19 % reduction. Ultimate tensile strength (UTS) increased by 6 % in the skin direction and 12.8 % in the flange direction for UFSW compared to FSW. SEM analysis indicated enhanced ductility in UFSW fractures. These results demonstrate UFSW's superiority in improving thermal management, microstructural properties, and mechanical performance of welded joints.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100257"},"PeriodicalIF":3.8,"publicationDate":"2024-10-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142421591","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancing bending strength in continuous drive friction welding of PEEK polymer cylinders through the innovative progressively increased welding area method","authors":"Chil-Chyuan Kuo ,&nbsp;Hua-Xhin Liang ,&nbsp;Song-Hua Huang ,&nbsp;Armaan Farooqui ,&nbsp;Shih-Feng Tseng","doi":"10.1016/j.jajp.2024.100255","DOIUrl":"10.1016/j.jajp.2024.100255","url":null,"abstract":"<div><div>The continuous drive friction welding (CDFW) stands out for its low energy consumption within the welding realm. Polyetheretherketone (PEEK) represents a high-performance engineering thermoplastic, falling under the polyaryletherketone family. Renowned for its outstanding mechanical, thermal, and chemical attributes, PEEK finds utility across a diverse array of industries. However, the discovery of numerous voids at the weld interface has revealed limitations in the mechanical properties of PEEK welded samples. This study introduces an innovative approach named progressively increased welding area (PIWA) method, to mitigate voids within the weld interface. In general, the Taguchi method was used to optimize the process parameters of CDFW of dissimilar PEEK round rods to reduce random efforts by the trial-and-error method. It was found that the proposed PIWA method can definitely enhance the bending strength of rotational friction welded samples due to reduction of voids inside the weld interface. The optimal process parameters for the CDFW with the PIWA method involve a rotational speed of 2500 rpm, a cone angle of 120°, a cone top width of 8 mm, and a feed rate of 0.1 mm/s. The most influential factor affecting the bending strength of the PEEK welded samples is the feed rate, followed by cone angle, rotational speed, and cone top width. Specifically, the contribution ratios for feed rate, cone angle, rotational speed, and cone top width are about 71 %, 20 %, 7 %, and 2 %, respectively. The confirmation tests showed that the bending strength of the PEEK welded samples using optimal process parameters can be increased by approximately 68 % compared with the maximum bending strength of 180 MPa using the conventional method with a cone angle of 180° The proposed PIWA method has industrial applicability and practical value because this technique can enhance the mechanical properties of PEEK welded samples under low environmental pollution and energy consumption.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100255"},"PeriodicalIF":3.8,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142421589","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel approach to control thermal induced buckling during laser welding of battery housing through a unilateral N-2-1 fixturing principle","authors":"Anand Mohan,&nbsp;Pasquale Franciosa,&nbsp;Dan Dai,&nbsp;Dariusz Ceglarek","doi":"10.1016/j.jajp.2024.100256","DOIUrl":"10.1016/j.jajp.2024.100256","url":null,"abstract":"<div><div>Battery housing (BH) in modern electric vehicles must meet demanding functional requirements. The design and geometry of the BH become intricate to prevent damage during collisions and to ensure absolute impermeability to gases and water during operation. Moreover, in the pursuit of a lightweight BH, manufacturers rely on high-strength 6xxx aluminium alloys, posing significant challenges for the welding processes. It is estimated that up to 30 m of weld length is required during the construction of battery housings including joining the lid and under-shield to the main structural frame and joining the ribs to the frame for standard vehicles. Due to the increasing use of thin sheets for lightweighting the structure, thermal-induced buckling may occur and generate critical dimensional unconformities going beyond design tolerances. This underpins the need to optimise fixturing design to control thermal-induced buckling.</div><div>This paper goes beyond the state-of-the-art “N-2-1″ approaches for fixturing thin and deformable parts and proposes the new principle of “unilateral N-2-1 fixturing”. The driving idea is adding unilateral restraints to the direction of thermal contraction, which ultimately causes buckling; and, keeping the direction where the thermal expansion occurs in a free state. The methodology is based on three main steps: (1) physics-based modelling of parts and fixtures using a thermo-mechanical FEA simulation; (2) calibration of the weld heat source using metallographic data; (3) validation using optical scanning technology. The methodology was demonstrated during the laser beam welding of a high-strength aluminium 6xxx thin deformable lid to a rigid high-strength 6xxx aluminium extrusion frame. Results indicated that the thermal induced buckling deformation was reduced from 15 mm, when using the state-of-the-art fixturing approach, to approximately 2 mm with the proposed methodology.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100256"},"PeriodicalIF":3.8,"publicationDate":"2024-09-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142421590","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"High strain rate tensile deformation of similar and dissimilar AA6082 and AA7075 friction-stir-welded blanks","authors":"E. Scharifi ,&nbsp;M. Kahlmeyer ,&nbsp;A. Suckau ,&nbsp;S. Lotz ,&nbsp;N. Sommer ,&nbsp;R. Delir Nazarlou ,&nbsp;D. Bailly ,&nbsp;U. Weidig ,&nbsp;K. Steinhoff","doi":"10.1016/j.jajp.2024.100254","DOIUrl":"10.1016/j.jajp.2024.100254","url":null,"abstract":"<div><div>Friction-stir-welding process has become an established solid-state technique for joining of dissimilar lightweight materials over the past decade by overcoming fundamental welding challenges such as solidification cracking, phase segregation and surface oxidation. Despite these unique capabilities, the resulting microstructure feature in the weld zone consisting of fine grains with a high dislocation density, challenges further heat treatment and forming processes. Hence, a high solution annealing temperature results in degradation of the adjusted microstructure and in a lower to reduced mechanical properties in case of dissimilar joints of precipitation-hardenable aluminum alloys. Subsequent hot forming therefore involves a great effort and requires further heat treatment steps. Thus, the present study investigates the effect of a recently introduced novel thermo-mechanical forming process on local deformation behavior of similar as well as dissimilar joints processed by friction-stir-welding technique of thin-walled AA6082 and AA7075 blanks. To avoid the complete elimination of the adjusted microstructure, the welding process is performed after a thermo-mechanical process consisting of solution annealing, die cooling and peak aging. Uniaxial tensile tests are then carried out at high strain rates ranging from <span><math><mover><mrow><mi>ε</mi></mrow><mi>˙</mi></mover></math></span> = 40 s^-1 to <span><math><mover><mrow><mi>ε</mi></mrow><mi>˙</mi></mover></math></span> = 400 s^-1. The results show an increase in yield and ultimate tensile strength as well as in total elongation after failure with increasing strain rates. As the strain rate increases, the flow stress of similar weld of AA7075 is higher than those of AA6082 and the dissimilar weld of AA6082 and AA7075. Local deformation measurements reveal higher strain localization in the welded zone for similar welds, which leads to micro-crack initiation and failure due to strain accumulation. Microstructure analysis shows very fine equiaxed grain structure in the nugget zone and homogenous distribution of precipitates after friction stir welding process, which explain the plastic deformation behavior.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100254"},"PeriodicalIF":3.8,"publicationDate":"2024-09-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142323138","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of the media tightness of a microform-fitted plastic/light metal composite","authors":"Moritz Mascher,&nbsp;Pia Wagner,&nbsp;Christian Hopmann","doi":"10.1016/j.jajp.2024.100253","DOIUrl":"10.1016/j.jajp.2024.100253","url":null,"abstract":"<div><p>Plastic/metal hybrid components made of amorphous thermoplastics such as polycarbonate and light metals such as aluminum offer potential to be used in modern automotive headlights to meet the high requirements for tolerances and surface quality. A microform-fit joining approach is used to join plastics and metals, which combines the advantages of material-fit and form-fit joining processes while at the same time avoiding some of the disadvantages of the respective joining approaches, such as stress peaks or the use of additional chemicals. For this purpose, the light metal component is microstructured through laser ablation. To ensure the functional safety of electrical components, the media tightness of the hybrid component is tested with a pressure drop test. An influence of the structure arrangement, the structure spacing and the molding compound on the media tightness can be determined. The highest media tightness can be achieved with a ring-shaped structural arrangement in which the microstructures are orientated orthogonally to the outlet direction of the test medium. The media permeability of a ring-shaped structure arrangement with a structure spacing of 500 µm is 0.42 cm³/s for test specimens made of aluminum and polycarbonate. As the value is below the threshold value of 12 cm³/s, watertightness up to an overpressure of at least 0.5 bar can be concluded.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100253"},"PeriodicalIF":3.8,"publicationDate":"2024-09-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000694/pdfft?md5=99e3d6f0213567ef7569418dfa402a69&pid=1-s2.0-S2666330924000694-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142240771","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Characterization and modeling of laser transmission welded polyetherketoneketone (PEKK) joints: Influence of process parameters and annealing on weld properties","authors":"Marcela Matus-Aguirre ,&nbsp;Benoît Cosson ,&nbsp;Christian Garnier ,&nbsp;Fabrice Schmidt ,&nbsp;André Chateau Akué-Asséko ,&nbsp;France Chabert","doi":"10.1016/j.jajp.2024.100252","DOIUrl":"10.1016/j.jajp.2024.100252","url":null,"abstract":"<div><p>Welding high-performance thermoplastics has gained popularity across various industries such as automotive, aerospace, and medical. Laser transmission welding (LTW) has emerged as an effective method for joining thermoplastic parts due to its precise control and high joint quality. PAEK (polyaryletherketone) are wide spreading over various industrial applications as a substitute to metals and thermosets when high durability and performance are required. Polyetherketoneketone (PEKK) is one of these PAEK and it has received less attention than PEEK until now. PEKK, being a semi-crystalline thermoplastic, requires additional care during processing due to its propensity to crystallize. This study presents both experimental and numerical investigations into LTW of PEKK molded parts, aiming to understand the influence of welding parameters and crystallinity on weld joint morphology and mechanical properties. PEKK plates, prepared in amorphous and semi-crystalline states, are subjected to LTW using a 975 nm diode laser. Material characterization confirms differences in crystallinity between the samples, which affect their thermal and optical properties, which are crucial for welding. Welding tests are conducted with varying laser power (between 75 and 95 W) and semi-transparent part thickness (2 and 4 mm). The morphology of joints is analysed. Assemblies undergo post-weld annealing treatment to examine its influence on weld crystallinity and consequent mechanical properties. Results reveal an anisotropic distribution of crystallinity within the heat-affected zone (HAZ). The depths of the molten layer (ML) and semi-crystalline layer (scL) vary with laser power and assembly type. A notable decrease in weld strength with laser power is highlighted, while annealing leads to enhanced crystallinity and improved weld strength. Despite variations, high weld strengths are achieved with annealing. Computational modelling elucidates the complex interplay between laser irradiation, temperature distribution, and crystallization kinetics observed experimentally. Overall, this comprehensive investigation provides valuable insights into optimizing LTW parameters for PEKK parts.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100252"},"PeriodicalIF":3.8,"publicationDate":"2024-09-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000682/pdfft?md5=24dcb89e6cc6e498459bac99b4908582&pid=1-s2.0-S2666330924000682-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142240770","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Dual-mode laser beam welding of similar and dissimilar material tab-to-busbar for electric vehicle battery pack","authors":"Nikhil Kumar ,&nbsp;Venkat Vivek Pamarthi ,&nbsp;Christopher Harris ,&nbsp;Elliot Burbidge ,&nbsp;Iain Masters","doi":"10.1016/j.jajp.2024.100250","DOIUrl":"10.1016/j.jajp.2024.100250","url":null,"abstract":"<div><p>The escalation in electric vehicle (EV) adoption necessitates advanced laser joining techniques for critical battery pack components. However, using a standard Gaussian single-mode laser for joining similar and dissimilar material combinations e.g. aluminium/aluminium (Al/Al), aluminium/copper (Al/Cu) for tab-to-busbar connections often led to defects such as cracks and intermetallic compound (IMC) formation. This paper investigates using a dual-mode laser consisting of a core and ring to overcome these issues. In this research, 0.3 mm Al and Cu tabs were welded with 1.5 mm Al and Cu busbars using a 6 kW IPG dual-mode laser at a high welding speed of 1 m s^-1. The study focussed on the effects of dual-mode parameters (i.e. core and ring beam power) and welding speed on tab-to-busbar connections, analysing the interplay between electrical contact resistance, temperature and IMC formation through electrical resistance tests, elemental and strength analysis. The results show, that using the ring beam along with the core beam reduces excessive melting and evaporation of Al and minimises the intermixing of Al and Cu solid solutions in the joint. In the Cu tab-to-Al busbar joint, increasing the ring beam intensity effectively reduces the convexity defect found with single-mode beam attributed to improved keyhole stability. Overall, in dual-mode laser welding, the ring beam protects the keyhole and reduces the IMC formation, while the core beam, with its high peak intensities, controls the penetration depth. This necessitates balancing both core and ring beam intensities for optimal weld quality. Further, the joint resistance for Cu tab-to-Cu busbar (51.90 μΩ) joint was the lowest followed by Cu tab-to-Al busbar (68.38 μΩ) joint, Al tab-to-Cu busbar (84.44 μΩ) joint and Al tab-to-Al busbar (114.12 μΩ) joint.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100250"},"PeriodicalIF":3.8,"publicationDate":"2024-09-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000669/pdfft?md5=5530b89d797a952fb8a294d5495f390b&pid=1-s2.0-S2666330924000669-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142151887","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"An energetic approach to the statistical analysis and optimization of friction welding processes applied to an aluminum-steel-joint","authors":"M. Winkler ,&nbsp;C. Rößler ,&nbsp;N. Harriehausen ,&nbsp;S. Jüttner ,&nbsp;D. Schmicker ,&nbsp;F. Trommer","doi":"10.1016/j.jajp.2024.100251","DOIUrl":"10.1016/j.jajp.2024.100251","url":null,"abstract":"<div><p>The present publication deals with an energy-oriented approach to the statistical analysis of rotational friction welding processes. To illustrate the methodological approach, it is applied to investigate the effects of energy flow on material flow behavior and joint quality during friction welding of an AA6060 alloy with a low-alloy 16MnCr5 filler steel. The influences of the setting parameters on the energetic states are first analyzed by means of an initial screening. The evaluation using process simulation and statistical methods enables the generation of regressive response surfaces for the friction power, the friction time and the resulting induced friction energy. Based on these findings, a second experimental field is formed and evaluated, which considers the interaction between the energy input of the frictioning stage and the workpiece forging. This new approach results in the functional separation of the frictioning and forging stage, which eliminates the usual statistical interaction effects and thus facilitates analysis and optimization. The qualitative result variable required for the purpose of interpreting the results is the ultimate tensile strength of the friction-welded joint. Additionally determined hardness curves provide information about the properties of the thermally influenced zone and strength-relevant process sequences. The result is that, in addition to the amount of energy induced, the frictional power with which the former is induced also has a considerable influence on the joint strength, as it influences the material flow and the properties of the joining zone.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100251"},"PeriodicalIF":3.8,"publicationDate":"2024-09-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000670/pdfft?md5=68ec14bd4d9234f6c5d6a20de1f68bbd&pid=1-s2.0-S2666330924000670-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142167346","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Fe/polymer joining via Fe/TiB2 composite structures via in-situ laser-induced reaction of Fe-Ti-B system: Effect of powder composition","authors":"Shaoyun Zhou,&nbsp;Koki Omiya,&nbsp;Yuto Ueda,&nbsp;Asuka Suzuki,&nbsp;Naoki Takata,&nbsp;Makoto Kobashi","doi":"10.1016/j.jajp.2024.100249","DOIUrl":"10.1016/j.jajp.2024.100249","url":null,"abstract":"<div><p>Achieving strong direct joining between steel and polymers through mechanical interlocking is crucial for developing multi-material structures, particularly in the automotive and aerospace industries. This study synthesized micro-scale structures on a pure Fe substrate (simulating interstitial-free (IF) steel) for mechanical interlocking with thermoplastic parts. Numerous submillimeter-scale Fe/TiB₂ composite particles were in-situ synthesized by laser scanning on the Fe-Ti-B powder mixture and well-bonded with the Fe substrate. The effects of powder composition (TiB₂ volume fraction) on the morphology, microstructure, and joint strength with PA6 were investigated. A TiB₂ volume fraction over 60 % was essential for the formation of the composite particles promoted by a TiB₂ skeletal structure. Higher TiB₂ volume fractions increased the area fraction of the composite particles and decreased the bonding ratio (adhesive) of the particles with the substrate due to poor adhesiveness at the edge of the laser-scanning line. A wider high-temperature region was generated at a higher TiB₂ volume fraction, suggesting that the reaction heat to form TiB₂ assisted the bonding of the particles with the substrate at the edge of the laser scanning line. The Fe/PA6 joint strength increased to approximately 30 MPa with increasing the TiB₂ volume fraction to 100 % and showed a linear correlation with the product of particle area fraction and bonding ratio. A higher TiB₂ volume fraction was preferable for enhancing the joint strength via the micro-scale structures synthesized by laser scanning on the Fe-Ti-B powder mixture. A combination of the micro-structuring process using a high fraction of TiB₂ with advanced joining technologies will contribute to manufacturing high-strength Fe/polymer hybrid parts.</p></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100249"},"PeriodicalIF":3.8,"publicationDate":"2024-09-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://www.sciencedirect.com/science/article/pii/S2666330924000657/pdfft?md5=53be598e789d8f527444022129922e10&pid=1-s2.0-S2666330924000657-main.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142151888","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}