Journal of Advanced Joining Processes最新文献

{"title":"Multi-objective optimization of welding-induced residual stress and deflection in 6082-T6 aluminum alloy using validated thermo-mechanical modeling","authors":"Hamidreza Rohani Raftar ,&nbsp;Amir Khodabakhshi ,&nbsp;Tomi Suikkari ,&nbsp;Antti Ahola ,&nbsp;Tuomas Skriko","doi":"10.1016/j.jajp.2025.100351","DOIUrl":"10.1016/j.jajp.2025.100351","url":null,"abstract":"<div><div>Welding of aluminum alloys often introduces residual stress and deflection, compromising dimensional precision and structural performance. This study investigates the influence of key process parameters of gas metal arc welding on the thermo-mechanical response of 6082-T6 aluminum alloy butt joints. A numerical method was developed and validated using experimental measurements of temperature distribution (thermocouples), deflection (3D laser scanning), and residual stress(X-ray diffraction). A full-factorial design of experiments (DOE) was conducted, varying clamping configuration, plate thickness, welding sequence, and cooling conditions. Analysis of variance (ANOVA) quantified main and interaction effects. The study identified a trade-off between deflection and residual stress, which was addressed through multi-objective optimization using a desirability function approach. Deflection was reduced from 1.44 mm (measured experimentally) to 0.6 mm under optimized conditions, while the minimum residual stress was 171 MPa, representing a decrease of approximately 12%. The optimum condition corresponded to a partially restrained clamping configuration, a plate thickness of 4 mm, a continuous single pass welding sequence, and natural air cooling. Predictive models based on ensemble regression techniques were constructed using the 72 DOE-based FEM cases and validated with experimental measurements to estimate responses and rank influential parameters. The models achieved an R² values of 0.93 for deflection and an R² value of 0.94 for residual stress. Consistency between statistical and predictive analyses confirmed the dominant factors. The optimization framework offers a data-driven approach to improve welded structural integrity and highlights the potential of integrated simulation and data analysis in materials processing and design.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100351"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145219494","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of varying stiffness on the interfacial failure behavior of isotactic polypropylene and porous alumina studied via DPD simulation","authors":"Yoshitake Suganuma,&nbsp;James A. Elliott","doi":"10.1016/j.jajp.2025.100343","DOIUrl":"10.1016/j.jajp.2025.100343","url":null,"abstract":"<div><div>This work studies a polymer–metal oxide bonded interface consisting of isotactic polypropylene (iPP) and a porous surface, and examines the impact of the stiffness of the polymeric component on the tensile strength of the interface using the dissipative particle dynamics (DPD) method. Our calculations reveal that an increase in the stiffness of iPP component leads to an increased tensile strength on the porous alumina even in an interfacial failure. The tensile failure mode observed on the porous surface is caused by the slippage of iPP component along the pore walls. An iPP component with a higher Young’s modulus is more resistant to deformation during tensile tests, which makes it difficult for the interfacial stress to reach the critical strain for the slippage, and thus results in an increased tensile strength of the bonded interface.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100343"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144917747","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":"Microstructure and mechanical properties of hand-held laser beam welded S700MC high-strength steel","authors":"Johannes Günther ,&nbsp;Robert Prowaznik ,&nbsp;Daniel Krug ,&nbsp;Simon Jahn ,&nbsp;Thomas Niendorf ,&nbsp;Thomas Wegener","doi":"10.1016/j.jajp.2025.100359","DOIUrl":"10.1016/j.jajp.2025.100359","url":null,"abstract":"<div><div>Hand-held laser beam welding (HLBW) has gained attention due to its flexibility, high welding speeds, and excellent joint appearance. Since research on this technique remains limited, the present study provides first insights into HLBW of S700MC high-strength low-alloy steel. Radiographic analysis reveals that joints with a low degree of porosity can be achieved, addressing a major challenge of manual welding. Mechanical characterization by hardness, V-notch impact, and tensile testing demonstrates good performance of the welded structure. The welded joint exhibits a yield strength of 686 MPa and a tensile strength of 778 MPa compared to 775 MPa and 840 MPa of the base material, respectively. Hardness measurements show a reduction from 280 HV0.5 in the base material to ≤ 240 HV0.5 in the fine-grained heat-affected zone, consistent with the observed strength decrease and within the limits of the ER100S-G filler wire. Despite a reduction in fracture elongation from 20 % to ≈ 10 %, the absorbed impact energy reaches 36.5 J, exceeding the value of 30 J being characteristic for the base material, indicating sufficient ductility. Microstructural analysis reveals distinct cementite-free upper and granular bainite, acicular and polygonal ferrite as well as various morphologies of martensite-austenite constituents in the fusion zone and at given distances to the fusion line. A cooling time t_8/₅ ≈ 6 s was determined, to eventually enable quantitative process–microstructure–property correlation. Overall, the study confirms that HLBW enables the production of mechanically sound welds in S700MC, eventually allowing for robust application of this emerging technology for joining of high-strength thermo-mechanical processed mildsteel.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100359"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145568213","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":"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}

{"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}

{"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}

{"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 (Al₂O₃) and titanium carbide (TiC) nanoparticles introduced into the fusion zone of laser welded AA6005 aluminium sheets via electrophoretic deposition (CuSO₄ bath, ∼40 nm nanoparticles, varying concentrations/times). Microstructural analysis revealed that the incorporation of both Al₂O₃ 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 Al₂O₃ coated samples and a 13% increase for TiC coated welds compared to the uncoated material. Notably, TiC outperformed Al₂O₃ at higher concentrations, exhibiting more uniform dispersion with reduced agglomeration and porosity. In contrast, Al₂O₃ 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}

{"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}

{"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}

{"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 CO₂, N₂, and O₂ in the mixture and wall geometry samples with N₂ and O₂ 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 O₂ 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}