Journal of Advanced Joining Processes最新文献

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Debonding-on-demand of vacuum-infused thermoplastic fibre-reinforced laminates with improved recyclability 提高可回收性的真空注入热塑性纤维增强层压板的按需脱粘
IF 4
Journal of Advanced Joining Processes Pub Date : 2025-12-01 Epub Date: 2025-11-26 DOI: 10.1016/j.jajp.2025.100364
V. Bekas, C. Hoffmann, V.C. Beber, K. Arnaut
{"title":"Debonding-on-demand of vacuum-infused thermoplastic fibre-reinforced laminates with improved recyclability","authors":"V. Bekas,&nbsp;C. Hoffmann,&nbsp;V.C. Beber,&nbsp;K. Arnaut","doi":"10.1016/j.jajp.2025.100364","DOIUrl":"10.1016/j.jajp.2025.100364","url":null,"abstract":"<div><div>Debonding-on-Demand (DoD) is key in enabling recyclability and modular design of lightweight composite structures. This work investigates the effectiveness of DoD mechanisms using resistive heating modified substrates and thermally expandable particles (TEPs) on structural adhesive bonding. Methyl methacrylate adhesives are applied on vacuum-infused thermoplastic GFRP laminates with an Elium© acrylic matrix. Characterisation includes thermal imaging, DSC, lap-shear testing and fracture surface analysis. To enable localised thermal DoD-triggering, modified substrates are fabricated with integrated resistive heating elements. Thermal stimulus is applied either externally (via oven) and locally (via resistive heating). The expansion of TEPs is confirmed by optical microscopy. The most effective DoD response occurs in specimens with modified substrates without TEP, attributed to significant softening of the adhesive above its glass transition temperature. Specimens with both structural adhesive and TEP show a moderate DoD effect, though the reference strength is lower due to TEP-induced disruptions within the adhesive. Externally heated triggering of TEP yields little DoD effect. Fracture surface analysis supports these findings, showing characteristic changes consistent with adhesive softening and cohesive strength reduction. Results highlight how the incorporation of localised resistive heating elements can allow an easier recycling and reversible joining, which contrary to TEPs, can be repeated.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100364"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145681467","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}
引用次数: 0
Process parameter optimization and bonding mechanism in dissimilar S45C/A6061 joints via novel sacrificing-sheet linear friction welding 新型牺牲片线性摩擦焊接不同S45C/A6061接头的工艺参数优化及连接机理
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-12-01 Epub Date: 2025-07-16 DOI: 10.1016/j.jajp.2025.100331
Furkan Khan, Takuya Miura, Yoshiaki Morisada, Kohsaku Ushioda, Hidetoshi Fujii
{"title":"Process parameter optimization and bonding mechanism in dissimilar S45C/A6061 joints via novel sacrificing-sheet linear friction welding","authors":"Furkan Khan,&nbsp;Takuya Miura,&nbsp;Yoshiaki Morisada,&nbsp;Kohsaku Ushioda,&nbsp;Hidetoshi Fujii","doi":"10.1016/j.jajp.2025.100331","DOIUrl":"10.1016/j.jajp.2025.100331","url":null,"abstract":"<div><div>Sacrificing-sheet linear friction welding (SSLFW) is a novel solid-state joining technique developed to address the challenges of dissimilar welding between S45C steel and A6061 aluminum alloy, which are difficult to join using conventional linear friction welding (LFW). In this method, a S45C center sheet is linearly oscillated while the two base materials, i.e., S45C and A6061, are pressed against it using a center-driven double-sided LFW machine. The center sheet acts as a sacrificial sheet, which is progressively expelled from the joint interface during welding owing to thermomechanical effect from each side, thereby enabling direct joining between the base materials. This study investigates the effects of key process parameters on mechanical properties and interfacial microstructure, and clarifies the bonding mechanism of SSLFW. Optimum welding conditions with 2 mm upset length, 300 MPa applied pressure toward A6061, 1 s preheat time, and 50 MPa preheat pressure produced sound, defect-free joints with a thin, continuous intermetallic compound (IMC) layer of approximately 100 nm. These conditions enabled simultaneous plastic deformation of both base materials through sacrificing role of center sheet and effective suppression of unbonded regions. The resulting as-welded joint achieved a peak tensile strength of ∼235.3 MPa, corresponding to a joint efficiency of ∼73 % with respect to the A6061 base metal. Post-weld artificial aging significantly exhibited hardness recovery on the A6061 side, enhancing the joint strength to ∼307 MPa and increasing joint efficiency to ∼96 %. These results demonstrate the high potential of SSLFW for sound dissimilar metal joining.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100331"},"PeriodicalIF":3.8,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144686359","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}
引用次数: 0
Surface cracks repair in AA6061-T6 aluminum alloys using friction stir processing 搅拌摩擦法修复AA6061-T6铝合金表面裂纹
IF 4
Journal of Advanced Joining Processes Pub Date : 2025-12-01 Epub Date: 2025-08-11 DOI: 10.1016/j.jajp.2025.100340
Fadi Al-Badour , Ahmad H. Bawagnih , Ahmed Ali , Rami K. Suleiman , Necar Merah
{"title":"Surface cracks repair in AA6061-T6 aluminum alloys using friction stir processing","authors":"Fadi Al-Badour ,&nbsp;Ahmad H. Bawagnih ,&nbsp;Ahmed Ali ,&nbsp;Rami K. Suleiman ,&nbsp;Necar Merah","doi":"10.1016/j.jajp.2025.100340","DOIUrl":"10.1016/j.jajp.2025.100340","url":null,"abstract":"<div><div>Friction Stir Welding (FSW) is an advanced solid-state joining technique that offers an effective solution for repairing surface cracks in aluminum alloys. This study investigates the repair of an artificially induced 2 mm square groove in AA6061-T6 aluminum alloy plate; resemble pre-repair preparation, using friction stir processing (FSP), incorporating an aluminum filler rod and silicon carbide (SiC) nanoparticles as a reinforcement to ensure complete crack sealing. FSP was conducted on both cracked and crack-free samples, with a focus on the impact of tool offset during the repair process. Tool offsets of 0 mm, 1.75 mm, and 3.5 mm were employed toward the advancing side to assess their influence on the repair process. Mechanical testing, microstructural characterization, temperature, and force analysis were performed to comprehensively evaluate the repair strategy. The repaired samples exhibited an average ultimate tensile strength (UTS) of approximately 180 MPa, closely matching the 186 MPa observed in crack-free bead-on-plate welds. Additionally, the microhardness at stir zone (SZ) improved to average values of 77 HV for 0 mm offset and 80 HV for 1.75 mm offset, compared to 70 HV in the bead-on-plate welds . Despite the presence of microstructural defects, the use of tool offset contributed to satisfactory mechanical performance. However, samples welded with 0 mm tool offset exhibited slightly superior mechanical properties. Overall, this research highlights the feasibility of using FSP, combined with SiC nanoparticles reinforced filler material and tool offset control, as a promising approach for effective surface crack repair in aluminum alloys, providing a foundation for further process optimization and industrial application.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100340"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144841611","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}
引用次数: 0
Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating 利用分散在Cu涂层中的Al2O3和TiC纳米颗粒控制AA6005激光焊接中的凝固裂纹
IF 4
Journal of Advanced Joining Processes Pub Date : 2025-12-01 Epub Date: 2025-08-16 DOI: 10.1016/j.jajp.2025.100344
M.H. Khan , S. Jabar , T.I. Khan , H.R. Kotadia , P. Franciosa
{"title":"Controlling solidification cracks in laser beam welding of AA6005 using Al2O3 and TiC nanoparticles dispersed in a Cu coating","authors":"M.H. Khan ,&nbsp;S. Jabar ,&nbsp;T.I. Khan ,&nbsp;H.R. Kotadia ,&nbsp;P. Franciosa","doi":"10.1016/j.jajp.2025.100344","DOIUrl":"10.1016/j.jajp.2025.100344","url":null,"abstract":"<div><div>Laser beam welding is a critical joining method for wrought 6xxx series aluminium (Al) alloys; however, its broader adoption is hindered by the susceptibility to solidification cracking, which undermines weld integrity and restricts the production of high-quality joints. To mitigate cracking susceptibility, this study explores a novel approach involving the use of alumina (Al<sub>2</sub>O<sub>3</sub>) and titanium carbide (TiC) nanoparticles introduced into the fusion zone of laser welded AA6005 aluminium sheets via electrophoretic deposition (CuSO<sub>4</sub> bath, ∼40 nm nanoparticles, varying concentrations/times). Microstructural analysis revealed that the incorporation of both Al<sub>2</sub>O<sub>3</sub> and TiC nanoparticles on AA6005 led to an overall 65% grain refinement, effectively preventing centreline cracking during welding. Lap shear testing demonstrated a significant improvement in joint strength, with a 10% increase for Al<sub>2</sub>O<sub>3</sub> coated samples and a 13% increase for TiC coated welds compared to the uncoated material. Notably, TiC outperformed Al<sub>2</sub>O<sub>3</sub> at higher concentrations, exhibiting more uniform dispersion with reduced agglomeration and porosity. In contrast, Al<sub>2</sub>O<sub>3</sub> showed a tendency toward particle clustering and pore formation at elevated concentrations, which limited its strengthening efficiency. This highlights the potential of nanoparticle reinforcement for enhancing the reliability and performance of laser welded 6xxx aluminium alloys.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100344"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144886019","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}
引用次数: 0
Electron beam welding parameters for copper and dissimilar copper joints: Review, research gaps, and future challenges 铜和异种铜接头的电子束焊接参数:回顾、研究空白和未来挑战
IF 4
Journal of Advanced Joining Processes Pub Date : 2025-12-01 Epub Date: 2025-09-17 DOI: 10.1016/j.jajp.2025.100350
Sathishkumar Duraisamy , Ana Horovistiz , Antonio Bastos , Bernardo Mascate , João M.S. Dias
{"title":"Electron beam welding parameters for copper and dissimilar copper joints: Review, research gaps, and future challenges","authors":"Sathishkumar Duraisamy ,&nbsp;Ana Horovistiz ,&nbsp;Antonio Bastos ,&nbsp;Bernardo Mascate ,&nbsp;João M.S. Dias","doi":"10.1016/j.jajp.2025.100350","DOIUrl":"10.1016/j.jajp.2025.100350","url":null,"abstract":"<div><div>Copper welding presents significant challenges due to its high thermal conductivity and reflectivity, making traditional welding methods largely ineffective. Electron Beam Welding (EBW) offers a promising solution but requires precise parameter control to achieve optimal results. This study is a systematic review following a structured search of Scopus and Web of Science. After title–abstract–full text screening using predefined inclusion criteria (experimental EBW of copper or copper–dissimilar joints reporting process parameters and weld performance), 163 peer-reviewed articles were retained. For each study, the authors extracted process parameters (accelerating voltage, beam current, welding speed, focus/defocus, beam oscillation), material characteristics (alloy type, thickness, surface preparation), and outcomes (penetration, porosity, microstructure, mechanical properties). Reported statistical measures were consolidated to quantify the dominant influences of the parameters, and a SWOT analysis, along with a research gap analysis, was performed. Research indicates that vacuum-based EBW effectively overcomes copper welding difficulties while producing superior joint quality compared to other fusion processes. EBW achieves deep weld penetrations of up to 30 mm with minimal defects in copper, producing joint strengths of up to 264 MPa, equivalent to approximately 95% of the base material strength. Key welding parameters, including beam current, welding speed, focus position, and oscillation patterns, significantly influence weld quality, with beam current exerting the strongest effect on penetration depth. When joining copper to different materials, careful beam positioning and oscillation techniques successfully control unwanted compound formation while maintaining joint strength. Key findings establish that beam current accounts for 81% of the variance in weld quality control; strategic beam positioning with 0.4–0.5 mm offsets optimizes dissimilar joints, achieving strengths of 250 MPa; oscillation patterns reduce porosity by 30% while controlling intermetallic formation; and significant research gaps remain in copper tube joining applications for thermal management systems. This framework enables precision joining of high-performance copper systems for next-generation energy and electronics applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100350"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145108666","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}
引用次数: 0
Residual strain and strain evolution of dissimilar aluminium-steel friction stir lap welding during lap shear tests 异种铝-钢搅拌摩擦搭接在搭接剪切试验中的残余应变及应变演化
IF 4
Journal of Advanced Joining Processes Pub Date : 2025-12-01 Epub Date: 2025-11-25 DOI: 10.1016/j.jajp.2025.100362
Sergio R. Soria , Florencia Malamud , Markus Strobl , Leonardo N. Tufaro , Hernán G. Svoboda
{"title":"Residual strain and strain evolution of dissimilar aluminium-steel friction stir lap welding during lap shear tests","authors":"Sergio R. Soria ,&nbsp;Florencia Malamud ,&nbsp;Markus Strobl ,&nbsp;Leonardo N. Tufaro ,&nbsp;Hernán G. Svoboda","doi":"10.1016/j.jajp.2025.100362","DOIUrl":"10.1016/j.jajp.2025.100362","url":null,"abstract":"<div><div>Friction Stir Lap Welding (FSLW) is a technique used to join dissimilar materials, such as aluminium alloys and steel sheets, applied in the automotive industry. The residual strain distribution generated during the process, strongly affects the mechanical performance and long-term durability of the welded components. In this study, the residual strains generated during FSLW of aluminium alloy and steel sheets were investigated using Bragg edge neutron imaging (BEI). Different combinations of thin aluminium alloy and steel sheets with thicknesses between 0.8 mm and 2 mm were analysed. 5052 and 5182 alloys, in combination with AISI 1010 carbon steel and dual phase (DP) 1000 steel were employed. Additionally, the evolution of the actual strain under lap shear tests was monitored. The presence of the steel inclusions was detected by neutron transmission imaging. The BEI results showed tensile residual strain along the longitudinal direction in the steel sheets after the welding process, in all cases displaying a M-shaped strain field. During the lap shear tests, a reduction of the actual tensile strains was observed due to the lateral contraction produced in the mechanical testing.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100362"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145614594","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}
引用次数: 0
Effect of process gas mixtures on weld material characteristics and bead geometry for wire-arc directed energy deposition 工艺气体混合物对电弧定向能沉积焊接材料特性和焊头几何形状的影响
IF 4
Journal of Advanced Joining Processes Pub Date : 2025-12-01 Epub Date: 2025-09-04 DOI: 10.1016/j.jajp.2025.100347
Michael Unger , Sebastian Zehetner , Thomas Klein , Aurel Arnoldt , Martin Schnall
{"title":"Effect of process gas mixtures on weld material characteristics and bead geometry for wire-arc directed energy deposition","authors":"Michael Unger ,&nbsp;Sebastian Zehetner ,&nbsp;Thomas Klein ,&nbsp;Aurel Arnoldt ,&nbsp;Martin Schnall","doi":"10.1016/j.jajp.2025.100347","DOIUrl":"10.1016/j.jajp.2025.100347","url":null,"abstract":"<div><div>Shielding gases are used in welding technologies to prevent contamination and protect the metallic melt from disadvantageous effects that air could cause on the weld. While argon is mostly used for gas metal arc welding of aluminum, this paper investigates the use of mixtures with traces of different gases. Various properties of the weld seams are assessed: Effects on bead geometry, microstructure, defects, and mechanical characteristics of the resulting material. Investigations were performed for single welds as well as directed energy deposited wire-arc specimens. For this purpose, single bead on plate with CO<sub>2</sub>, N<sub>2</sub>, and O<sub>2</sub> in the mixture and wall geometry samples with N<sub>2</sub> and O<sub>2</sub> were manufactured and subsequently analyzed. Nitrogen in the gas mixture is reducing the bead and deposit width and decreasing the grain size compared to the reference sample. This grain size reduction is due to the formation of nitrides in the weld material acting as nucleants for new grains. Nitrides were identified by energy dispersive X-ray spectroscopy. Furthermore, nitrogen is reducing the number of pores but not significantly their volume fraction. A similar effect is reported for used amounts of O<sub>2</sub> on smaller scale. The characteristic mechanical strength values are comparable to reported data, but the elongation is reduced when nitrogen is present in the shielding gas mixture.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100347"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145044702","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}
引用次数: 0
Friction stir welding tool trajectory error on the load capacity of EN AW-2024-T3 aluminum alloy joints 搅拌摩擦焊刀具轨迹误差对EN AW-2024-T3铝合金接头承载能力的影响
IF 3.8
Journal of Advanced Joining Processes Pub Date : 2025-12-01 Epub Date: 2025-06-27 DOI: 10.1016/j.jajp.2025.100325
Magdalena Bucior , Rafał Kluz , Andrzej Kubit , Hamed Aghajani Derazkola , Enrico Cestino , Ján Slota
{"title":"Friction stir welding tool trajectory error on the load capacity of EN AW-2024-T3 aluminum alloy joints","authors":"Magdalena Bucior ,&nbsp;Rafał Kluz ,&nbsp;Andrzej Kubit ,&nbsp;Hamed Aghajani Derazkola ,&nbsp;Enrico Cestino ,&nbsp;Ján Slota","doi":"10.1016/j.jajp.2025.100325","DOIUrl":"10.1016/j.jajp.2025.100325","url":null,"abstract":"<div><div>This study investigates the influence of tool trajectory deviations on the load capacity and material flow of friction stir welded (FSW) overlap joints made of EN AW-2024-T3 aluminum alloy. Given that robotic movement is inherently burdened with deviation errors from a theoretically linear trajectory, this study aimed to assess the impact of these deviations on weld quality. Since the FSW-capable robot has low stiffness, a HAAS TM1P milling machine was used to simulate the robot's motion, incorporating recorded deviation errors. The welding process of 1 mm thick sheets was first conducted under ideal rectilinear conditions, establishing optimal parameters: feed rate of 200 mm/min, tool rotational speed of 1517 rpm, and plunge depth of 1.46 mm. Subsequently, controlled trajectory errors with standard deviations ranging from 0.05 mm to 0.2 mm were introduced into the milling machine’s movement to replicate robotic deviation. The results indicate that trajectory deviations with a standard deviation of up to 0.1 mm do not significantly affect the load capacity (increase from 1.01% to 1.95%) but increase dispersion in mechanical performance (2.22% - 2.5%). SEM analysis revealed that when trajectory errors exceeded 0.15 mm, material folding and microcracks appeared, compromising weld integrity. Furthermore, multi-criteria optimization demonstrated that compensating for trajectory deviations is possible by adjusting welding parameters—specifically, reducing the feed rate to increase heat accumulation. This approach enables the production of welds with a minimal decrease in load capacity (1.55% lower than an ideal trajectory weld), mitigating the negative effects of robotic trajectory errors. The use of a feed rate of <em>x<sub>2</sub></em> = 296 mm/min and a rotational speed of <em>x<sub>3</sub></em> = 800 rpm allows for achieving a load capacity of the joints with an average value of 5.36 kN with a standard deviation of σ<sub>F</sub> = 0.07 kN.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100325"},"PeriodicalIF":3.8,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144556740","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}
引用次数: 0
Comparative study of inertia and continuous drive friction welding processes based on equivalent energy input 基于等效能量输入的惯性与连续驱动摩擦焊接工艺对比研究
IF 4
Journal of Advanced Joining Processes Pub Date : 2025-12-01 Epub Date: 2025-07-29 DOI: 10.1016/j.jajp.2025.100337
Carina Vauderwange , Dirk Lindenau , Heinz Palkowski , Hadi Mozaffari Jovein
{"title":"Comparative study of inertia and continuous drive friction welding processes based on equivalent energy input","authors":"Carina Vauderwange ,&nbsp;Dirk Lindenau ,&nbsp;Heinz Palkowski ,&nbsp;Hadi Mozaffari Jovein","doi":"10.1016/j.jajp.2025.100337","DOIUrl":"10.1016/j.jajp.2025.100337","url":null,"abstract":"<div><div>Rotary friction welding can be performed using either continuous drive friction welding (CDFW) or inertia friction welding (IFW), which utilizes stored energy in a flywheel. Historically, these methods have distinct applications and geographic preferences: IFW is prevalent in the US, especially for superalloys, while CDFW is more common in Europe, focusing on automotive materials like steel and aluminum. This study presents a comparative analysis of both welding techniques using the same friction welding machine to minimize external variables. The free-machining steel AISI 1215, chosen for its banded microstructure, serves as the specimen material. The comparison is based on the same energetic input of 82.8 kJ to ensure consistency. However, IFW experienced significant losses due to internal friction, which further decelerated the spindle and reduced the effective weld energy to 68 kJ. Key findings include differences in deformation behavior and weld formation efficiency. CDFW exhibits a softer deformation, with principal shortening occurring during the forge phase due to axial force, resulting in large equiaxed inclusions in the weld zone. Additionally, less upset is generated with the same calculated energy input. In contrast, IFW demonstrates sharper deformation, with main shortening in the friction phase, achieving greater total upset. The combination of axial force and torque produces a spiralized material flow and finely dispersed inclusions due to high shear forces. These insights highlight the distinct advantages and characteristics of each welding technique, providing valuable information for their respective applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100337"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144750365","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}
引用次数: 0
Comparison of the economic efficiency and sustainability of two debonding processes for structurally bonded sills 两种结构粘接工艺的经济效率和可持续性比较
IF 4
Journal of Advanced Joining Processes Pub Date : 2025-12-01 Epub Date: 2025-07-25 DOI: 10.1016/j.jajp.2025.100332
Alex Jordan , Lucas Hermelingmeier , Julian Gilich , Gerson Meschut , Marco De Santis , Alexander Schlüter
{"title":"Comparison of the economic efficiency and sustainability of two debonding processes for structurally bonded sills","authors":"Alex Jordan ,&nbsp;Lucas Hermelingmeier ,&nbsp;Julian Gilich ,&nbsp;Gerson Meschut ,&nbsp;Marco De Santis ,&nbsp;Alexander Schlüter","doi":"10.1016/j.jajp.2025.100332","DOIUrl":"10.1016/j.jajp.2025.100332","url":null,"abstract":"<div><div>In light of growing demands for resource efficiency and sustainability in vehicle engineering, the environmentally compatible separation of structural adhesive joints is gaining increasing relevance. This study presents a comparative analysis of two physically based debonding methods: the established hot-air process and a cryogenic cold process based on liquid nitrogen (LN<sub>2</sub>). The primary objective is to assess the ecological impact and process-related sustainability of both approaches.</div><div>Experimental investigations were conducted on a component-representative triple-sheet structure that simulates common automotive flange joints. Thermal input was applied either by convective heating using a hot air gun or by direct cooling through a contact-based LN<sub>2</sub> tool. The resulting temperature profiles were recorded using spatially distributed thermocouples. Subsequently, the outer panel was selectively debonded to replicate a repair scenario, and the mechanical integrity of the remaining adhesive joint was evaluated through Mode I testing of l-shaped specimens. Process data served as input for an Life Cycle Assessment (LCA) according to DIN EN ISO 14,040.</div><div>The cryogenic method achieved a 40 % reduction in carbon footprint compared to the hot-air process (0.337 kg vs. 0.559 kg CO<sub>2</sub>-equivalents), primarily due to its shorter process time and more efficient heat transfer. While the hot-air method’s impact is mainly driven by electrical energy use, that of the cold method stems from cryogenic media consumption. Notwithstanding certain disadvantages in specific impact categories, the LN<sub>2</sub>-based process exhibits a superior overall ecological performance and signifies a promising solution for repair- and recycling-oriented adhesive separation in structural vehicle applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100332"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144750366","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}
引用次数: 0
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