Journal of Advanced Joining Processes最新文献

{"title":"Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding","authors":"Sungyo Jung ,&nbsp;Gi Taek Oh ,&nbsp;Seungjin Jung ,&nbsp;Chungsik Yoon","doi":"10.1016/j.jajp.2025.100311","DOIUrl":"10.1016/j.jajp.2025.100311","url":null,"abstract":"<div><div>Flux-cored arc welding (FCAW) generates hazardous byproducts such as welding fumes and hexavalent chromium (Cr(VI)), posing significant health and environmental risks. This study investigated the effectiveness of modifying specific flux components in flux-cored wires (FCWs) to reduce these emissions. One base FCW and ten flux-modified FCWs were tested under controlled conditions, capturing emissions for gravimetric and Cr(VI) analysis. Flux compositions were determined using X-ray fluorescence. Statistical analyses, including difference tests, correlation, and multiple linear regression, were conducted to evaluate the association between the content of flux components and emission rates. Sodium (Na) content in the flux was positively associated with increased emission of welding fumes and Cr(VI), while titanium (Ti) content showed a negative association. Increasing the contents of fluorine (F), potassium (K), and chromium (Cr) in the flux raised welding fume emission but reduced Cr(VI) emissions. Strategic adjustments in flux composition, specifically increasing Ti, silicon (Si) and zirconium (Zr) while decreasing Cr, K, Na, and F content, significantly reduced welding fume emissions by up to 32.4 % and Cr(VI) emissions by 95.4 %. These findings suggest that tailoring flux composition can effectively mitigate occupational and environmental hazards, enhance welder safety, and promote more sustainable FCAW practices without compromising welding performance.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100311"},"PeriodicalIF":3.8,"publicationDate":"2025-05-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144090419","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":"Enhancing mechanical properties and isotropy in ultrasonic assisted powder bed fusion of metals using a laser beam (PBF-LB/M) via Dual Exposure","authors":"Sebastian Platt ,&nbsp;Jan Wegner ,&nbsp;Arno Elspaß ,&nbsp;Hanna Schönrath ,&nbsp;Stefan Kleszczynski","doi":"10.1016/j.jajp.2025.100307","DOIUrl":"10.1016/j.jajp.2025.100307","url":null,"abstract":"<div><div>Parts produced via powder bed fusion of metal using a laser beam process often exhibit mechanical anisotropy due to the directional solidification, complicating part design. This study explores the use of ultrasonic-assistance to reduce anisotropy by promoting microstructural homogenization through increased nucleation. Specimens were fabricated using a dual exposure strategy, to avoid the challenges that arise with the in-situ ultrasonic excitation of a powder bed. Furthermore, a comprehensive microstructural as well as mechanical analysis was carried out. Microstructural analysis revealed increased grain orientation variation in ultrasonically treated specimens. Mechanical testing showed improved tensile and yield strength and reduced anisotropy, with tensile and yield strength anisotropy decreasing by 55.4 % and 46.1 %, respectively. Despite increased surface roughness, ultrasonic treatment reduced anisotropy in ductility-related properties, highlighting its potential to improve the performance of additively manufactured parts by reducing anisotropy and simultaneously enhancing mechanical properties.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100307"},"PeriodicalIF":3.8,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143921669","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":"Relationship between the developed interfacial area ratio and the adhesion of the bonded joint","authors":"Benjámin Márk Körömi ,&nbsp;Zoltán Weltsch ,&nbsp;Miklós Berczeli","doi":"10.1016/j.jajp.2025.100310","DOIUrl":"10.1016/j.jajp.2025.100310","url":null,"abstract":"<div><div>Bonding technologies have evolved significantly over the past decades, playing a crucial role in the field of joining technologies. To date, however, there is no consensus among research groups as to whether surface texture or surface wettability, or both, affect the strength of bonded joints. Bonded joints, as a bonding technique, are highly dependent on the chemical composition of the adhesive or binder. It is also important to note that the strength and the quality of a bonded joint is greatly influenced by surface adhesion and its related phenomena. From a materials science perspective, surface adhesion is characterised by the level of surface wetting and the total surface energy. In addition, microtopographies and other geometrical features play a key role in bond formation. In this research, the goal is to create controlled microtopographies on DP600 steel surfaces, mainly using femtosecond pulsed laser surface treatment techniques. The ability of adhesives to fill microtopographies specifically, the extent and manner in which micro-scale geometries and structures are filled is also investigated. This allows for the establishment of correlations between the strength of adhesive bonds and the shape characteristics of the microtopography, both in the surface-activated and non-surface-activated states.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100310"},"PeriodicalIF":3.8,"publicationDate":"2025-05-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143941190","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":"Optimizing microstructure and performance: The impact of pre-deformation and rotational speed on friction stir processed Cu-W composites","authors":"Masoomeh Oliaei,&nbsp;Roohollah Jamaati,&nbsp;Hamed Jamshidi Aval","doi":"10.1016/j.jajp.2025.100308","DOIUrl":"10.1016/j.jajp.2025.100308","url":null,"abstract":"<div><div>This study investigated the effects of pre-deformation induced by asymmetric rolling on copper-based metal, as well as rotational speed during friction stir processing, on the microstructure, mechanical properties, and electrical conductivity of tungsten-reinforced copper matrix composites. The results show that increasing the rotational speed up to 800 rpm leads to a more uniform distribution of tungsten particles within the stir zone. However, at rotational speeds above 800 rpm, the distribution of tungsten reinforcing particles becomes less uniform. The accumulated strain in the stir zone increases from 0.3056 to 0.3967 s^-1 as the rotational speed rises from 600 to 1200 rpm. Additionally, as the tool rotational speed increases from 600 to 1200 rpm, the grain size in the stir zone grows from 6.2 ± 0.7 to 13.2 ± 1.5 µm. The Cu-W composite processed at a tool rotational speed of 800 rpm achieves the highest values in hardness (124.9 ± 8.9 HV0.1), ultimate tensile strength (307.4 ± 11.8 MPa), tensile toughness (92.1 ± 1.1 MJ/m³), and electrical conductivity (92.8 ± 1.3 %IACS). Compared to the as-rolled copper-based metal, the electrical conductivity of the Cu-W composite fabricated at 800 rpm increases by 8.8 %.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100308"},"PeriodicalIF":3.8,"publicationDate":"2025-05-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143921668","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":"Friction stir processing of AA1050/AA5052 composite produced by accumulative roll bonding process: Microstructure and mechanical properties","authors":"Hamid Partoyar ,&nbsp;Hamid Reza Jafarian ,&nbsp;Hamed Roghani ,&nbsp;Ahad Mohammadzadeh ,&nbsp;Akbar Heidarzadeh","doi":"10.1016/j.jajp.2025.100306","DOIUrl":"10.1016/j.jajp.2025.100306","url":null,"abstract":"<div><div>A layered composite of AA1050-AA5052 alloys was fabricated through roll bonding, and accumulative roll bonding (ARB) and subsequently subjected to friction stir processing (FSP). In this process, the annealed AA5052 and AA1050 sheets are used as raw materials. At first, preheating at 200 °C for 6 min preceded the rolling process in an induction furnace, achieving a 67 % reduction in the cross-sectional area. Then, two ARB stages were conducted. At the flow, the FSP process was conducted at constant transversal speeds of 750 rpm and 1180 rpm. Microstructural details were analyzed using optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD). Mechanical properties were assessed through tensile test, microhardness measurement, and wear test. The results showed that recrystallization occurred due to FSP applied to the rolled sheet. The tensile strength after ARB and FSP was measured as 270 and 150 MPa, respectively. These values show an increase of 3.3 times and 1.8 times, respectively, compared to annealed AA1050. The maximum elongation after ARB and FSP was measured at about 9 and 30 %. Work hardening and grain refinement, respectively, had a significant role in increasing the elongation of the AA1050/AA5052 composites created by ARB and FSP. Furthermore, FSP enhanced the wear resistance of the AA1050-AA5052 composite created with two ARB steps by 70 %.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100306"},"PeriodicalIF":3.8,"publicationDate":"2025-04-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143903677","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":"High-brightness laser welding with beam wobbling: Achieving high-strength Al/Steel joints for battery busbars","authors":"M Chelladurai Asirvatham ,&nbsp;Iain Masters ,&nbsp;Geoff West ,&nbsp;Paul Haney","doi":"10.1016/j.jajp.2025.100305","DOIUrl":"10.1016/j.jajp.2025.100305","url":null,"abstract":"<div><div>Laser welding of aluminium tabs to nickel-plated interstitial-free (IF) steel was investigated using a high-brightness, single-mode laser with beam wobbling. The influence of interaction time, controlled by wobble amplitude and traverse speed, regulating energy distribution on weld microstructure and mechanical properties was systematically studied. Short interaction times (&lt;25 µs) and large inter-wobble distances (&gt;150 µm) minimized intermetallic compound (IMC) formation and maximized weld strength. Optimizing these parameters (wider wobble amplitudes of 0.6–0.8 mm and faster speeds of 75–100 mm/s) suppressed IMC-induced cracking, resulting in microstructures containing Fe-rich IMCs and Al-Fe₄Al₁₃ eutectic phases. Conversely, lower wobble amplitudes (&lt;0.6 mm) and slower speeds (50–75 mm/s) promoted crack-prone Al-rich Fe₂Al₅ phases. Optimized welds exhibited excellent fatigue performance, withstanding 1 million cycles at 175 N, demonstrating the potential for using lighter, cost-effective aluminium busbars in battery interconnect applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100305"},"PeriodicalIF":3.8,"publicationDate":"2025-04-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143899316","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":"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":"2025-04-22","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}

{"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":"2025-04-15","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}

{"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":"2025-04-04","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}

{"title":"Direct bonding mechanism of titanium and PET resin via heating and pressurization: Influence of bubble dynamics on bonding strength","authors":"Katsuyoshi Kondoh ,&nbsp;Nodoka Nishimura ,&nbsp;Kazuki Shitara ,&nbsp;Shota Kariya ,&nbsp;Ke Chen ,&nbsp;Junko Umeda","doi":"10.1016/j.jajp.2025.100301","DOIUrl":"10.1016/j.jajp.2025.100301","url":null,"abstract":"<div><div>In response to growing environmental concerns, the transportation industry, including automotive and aerospace sectors, has emphasized improving fuel efficiency and reducing carbon dioxide emissions. To achieve significant weight reduction, multi-material design strategies that strategically utilize different materials based on their properties are being adopted. This trend highlights the need for advanced joining technologies capable of bonding dissimilar materials, such as metals and polymers or resins, while maintaining structural integrity and lightweight performance. This study investigates the direct bonding mechanism between pure titanium (Ti) and polyethylene terephthalate (PET) resin using a simple heating and pressurization process. Bubble formation at the bonding interface, a critical factor influencing joint strength, was analyzed through in-situ observation. Results show that controlled bubble dynamics enhance bonding by creating localized pressure, while excessive bubbles act as defects. Optimal bonding conditions were identified at 200–300 °C with relatively high bonding shear stress. X-ray photoelectron spectroscopy revealed the formation of Ti-C bonds, confirming strong chemical interactions at the interface. Additionally, pyrolysis gas chromatography-mass spectrometry identified ethylene glycol as a key component in bubble generation during thermal decomposition of PET. The findings highlight the significance of surface preparation, thermal control, and bubble management in achieving high bonding strength. This research provides insights into sustainable and efficient methods of dissimilar materials that can improve recyclability and support the development of advanced lightweight structures.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100301"},"PeriodicalIF":3.8,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143738514","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}