Journal of Advanced Joining Processes最新文献

{"title":"Corrigendum to “Enhancing bending strength in continuous drive friction welding of PEEK polymer cylinders through the innovative progressively increased welding area method” [Journal of Advanced Joining Processes 10 (2024) 100255]","authors":"Chil-Chyuan Kuo,&nbsp;Hua-Xhin Liang,&nbsp;Song-Hua Huang,&nbsp;Armaan Farooqui,&nbsp;Shih-Feng Tseng","doi":"10.1016/j.jajp.2024.100258","DOIUrl":"10.1016/j.jajp.2024.100258","url":null,"abstract":"<div><div>The authors regret missing to add the contract number NSTC 113–2221-E-131-023 to the funding statement.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100258"},"PeriodicalIF":3.8,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143101730","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 comprehensive techno-economic and environmental comparison of plasma-treated adhesive-bonded thermoplastic composites","authors":"Chiara Mandolfino,&nbsp;Lucia Cassettari,&nbsp;Marco Pizzorni,&nbsp;Luigi Benvenuto,&nbsp;Enrico Lertora","doi":"10.1016/j.jajp.2024.100268","DOIUrl":"10.1016/j.jajp.2024.100268","url":null,"abstract":"<div><div>Thermoplastic composites are gaining attention for their ability to support a circular economy, shifting away from traditional cost-driven design. Unlike thermoset composites, commonly used in automotive and aerospace sectors, thermoplastic composites offer recyclability, promoting environmental and economic sustainability. Adhesive bonding in thermoplastic composites provides even stress distribution, maintaining structural integrity and reducing delamination risks, which is crucial for lightweight design in transport and renewable energy applications. Optimising adhesive bonded joints is essential to improve structural integrity, efficiency and sustainability. This involves balancing technical, economic and environmental factors, with surface preparation, plasma treatment in particular, playing a key role.</div><div>This paper provides a comprehensive techno-economic-environmental comparison of adhesive bonded joints. The study integrates cost-effectiveness, production efficiency and environmental impact assessments to guide informed decision-making. The methodology includes preparing substrates with low-pressure plasma surface treatments, forming adhesive-bonded joints with different adhesives, and optimising process parameters using Response Surface Methodology (RSM). A Life Cycle Assessment (LCA) on optimised scenarios enhances Tensile Shear Strength (TSS). The study concludes with a comprehensive comparison, offering insights for resilient, efficient and sustainable engineering solutions.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100268"},"PeriodicalIF":3.8,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142660902","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":"Improving the joint strength of thermoplastic composites joined by press joining using laser-based surface treatment","authors":"Alexander Liebsch ,&nbsp;Daniel Wohlfahrt ,&nbsp;Thomas Kuntze ,&nbsp;Levin Schilling ,&nbsp;Jana Gebauer ,&nbsp;Robert Kupfer ,&nbsp;Niels Modler ,&nbsp;Andrés Fabián Lasagni ,&nbsp;Maik Gude","doi":"10.1016/j.jajp.2024.100260","DOIUrl":"10.1016/j.jajp.2024.100260","url":null,"abstract":"<div><div>Fibre-reinforced thermoplastic composites (TPC) provide an automated and cost-effective solution for their use in lightweight structures in series production. The combination of different material configurations allows the design of highly stress tolerant components. Previous studies demonstrated that the combination of TPC sheets, TPC hollow profiles and injection moulding compounds is even suitable for crash-relevant automotive parts. All three components are combined during the injection moulding process. To prevent collapse, the part must remain in a consolidated state and cannot be preheated. However, this results in poor adhesion between the hollow profile, the bulk material, and the TPC sheet. Previous studies have shown that the bonding strength between the hollow profile and the injection moulding compound can be increased by surface pre-treatment using laser structuring and plasma technology. In this work, laser structuring is employed to enhance the bonding strength between the hollow profile and the TPC sheet. Microscopy analysis is used to investigate the resulting surface morphology. Subsequently, single-lap-shear (SLS) specimens are produced by pressing the TPC sheets onto the flat part. The resulting bonding strengths are then evaluated by tensile shear tests. The study analyses the impact of various pre-treatment parameters on the bonding strength. Furthermore, it investigates the effect of sheet temperature on the bonding strength, including specimens without pre-treatment. Finally, the results of the surface treatment of hollow composite profiles are discussed.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100260"},"PeriodicalIF":3.8,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142550552","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":"Ablation treatment of CFRP via nanosecond pulsed Ytterbium-doped fiber laser: Effects of process parameters on surface morphology and shear strength of adhesive bonded joints","authors":"Chiara Mandolfino ,&nbsp;Fabrizio Moroni ,&nbsp;Marco Pizzorni","doi":"10.1016/j.jajp.2024.100270","DOIUrl":"10.1016/j.jajp.2024.100270","url":null,"abstract":"<div><div>Adhesive bonding is the joining technique that provides the maximum exploitation of Carbon Fiber Reinforced Polymers (CFRPs) for structural applications. However, it is necessary to attain a high-strength adhesive bond, achieved by removing surface contaminants, such as mold release agents, and simultaneously generating a surface structure suitable to increase the actual contact surface area. The purpose of the research work presented in this paper is to evaluate the effect of process parameters of a nanosecond pulsed laser pre-bonding surface treatment on the ablation of thermoset matrix CFRP substrates. In particular, the link between the volume of ablated material and the tensile shear strength (TSS) of adhesive bonded joints was evaluated by lap-shear tests, profilometer surveys, and Scanning Electron Microscope (SEM) analysis. ANOVA and regression models were used to highlight the influence of laser parameters, with power emerging as the most significant factor, and energy density proving pivotal for joint strength. Line spacing was also significant, while scanning direction had negligible impact. The key outcomes of the study demonstrated that controlled laser ablation plays a critical role in determining joint performance. A negative correlation was found between TSS and the thickness of ablated material, indicating that excessive ablation weakens the bond. Optimal joint strength was achieved with moderate fiber exposure while maintaining matrix integrity, emphasizing the need for precise control over laser parameters. Fracture surface analyses revealed distinct failure mechanisms, ranging from cohesive failure within the adhesive layer to interfacial failure at the fiber-matrix boundary, depending on the ablation conditions. The findings provide clear guidelines for optimizing laser surface treatments to enhance the structural performance of CFRP adhesive joints in practical applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100270"},"PeriodicalIF":3.8,"publicationDate":"2024-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142757453","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 electrical quality and long-term stability of aluminum ground stud connections in automotive applications","authors":"Viktor Haak,&nbsp;Keke Yang,&nbsp;Gerson Meschut","doi":"10.1016/j.jajp.2024.100262","DOIUrl":"10.1016/j.jajp.2024.100262","url":null,"abstract":"<div><div>The rapid advancement in the electrification of modern vehicles has led to a continuous increase in electrical consumers for various comfort and safety functions. Ground studs serve as the electrical interface between the conductive vehicle body and the onboard network. Drawn arc stud welding is an economical and established joining process for producing ground stud joints. The circuits in the onboard network are increasingly subject to greater demands regarding current-carrying capacity and long-term stability. Reliable signal and power transmission require minimal contact resistance at the electrical connection points of the ground stud system and must withstand various operating and environmental conditions over the entire service life. In this study, a ground stud made of AlMg5, with a ZnNi-coated steel cap nut was used on a 2.0 mm thick sheet of AlMg3. The electrical connection of the ground studs was made using tinned copper cable lugs and 35 mm² cables. To analyze the electrical resistance behavior in an accelerated test, the ground studs were subjected to a superimposed load with a cyclic current profile for 1008 h under changing climatic conditions. The results show that under the chosen operational and environmental conditions, accelerated aging and intermittent resistance behavior occur. A characteristic drop in resistance during the test indicates the failure point of the electrical connection. The cause of failure can be attributed to media penetration into the electrical contact zone. A failure of the electrical connection was observed after 512 h.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"10 ","pages":"Article 100262"},"PeriodicalIF":3.8,"publicationDate":"2024-10-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142533009","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 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}