Journal of Advanced Joining Processes最新文献

{"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>x₂</em> = 296 mm/min and a rotational speed of <em>x₃</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_F = 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}

{"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}

{"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 (LN₂). 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 LN₂ 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 CO₂-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 LN₂-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}

{"title":"LSDF-Net: An efficient lightweight defect detection method for ultrasonic welding surfaces","authors":"Shuhang Zhang ,&nbsp;Xin Jin ,&nbsp;Zhijiang Lou ,&nbsp;Sen Wang ,&nbsp;Shan Lu ,&nbsp;Yifan He","doi":"10.1016/j.jajp.2025.100339","DOIUrl":"10.1016/j.jajp.2025.100339","url":null,"abstract":"<div><div>This paper proposes LSDF-Net, a lightweight and high-speed detection network designed to address the challenges of insufficient accuracy and high computational cost in ultrasonic welding surface defect detection. Built upon the YOLOv8 architecture, LSDF-Net integrates a Dynamic Surface Detail Fusion Module (DSDFM) to enhance multi-scale feature representation and introduces a Lightweight Shared Convolution and Separate Batch Normalization detection head (LSCSBD) to reduce parameters and accelerate inference. In addition, a LAMP-based pruning strategy is applied, which achieves a 67% reduction in model size and a 48% reduction in computational cost with almost no performance degradation. Experimental results on both a self-constructed ultrasonic welding defect dataset and the public NEU-DET dataset demonstrate that LSDF-Net achieves the best overall performance, striking an excellent balance between accuracy and real-time inference. These results highlight its strong potential for real-time industrial defect detection applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100339"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144925754","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":"Investigation of the weld characteristics of AA6016-T4 friction stitch welds in overlap configuration and the influence of stitch length on static and fatigue strength","authors":"Dominik Walz,&nbsp;Stefan Weihe,&nbsp;Martin Werz","doi":"10.1016/j.jajp.2025.100363","DOIUrl":"10.1016/j.jajp.2025.100363","url":null,"abstract":"<div><div>High-strength, age-hardenable aluminum alloys in car body construction challenge conventional joining methods — especially in mixed-material body structures, as fusion welding is prone to hot cracking and to hydrogen porosity. As a solid-state process, friction stir welding circumvents these challenges and typically produces joints with a higher strength than fusion welding, particularly in high-strength aluminum alloys. While friction stir spot welding guns are commercially available, the joints produced with them exhibit significantly lower strength compared to linear welds. To address this issue, a friction stir welding gun capable of producing short stitch welds was developed for a possible application in car body manufacturing.</div><div>This work investigates friction stitch welds in AA6016-T4 sheet overlap joints and quantifies how the stitch length influences static strength, fatigue performance, hardness, and microstructure, compared to a continuous friction stir welded (FSW) joint. Short stitch welds obtained the highest lap-shear strength, achieving up to 83% joint efficiency, while longer welds reached between 65% and 68%. Metallography confirmed overlap-specific features, such as cold-lap imperfections in the weld, and showed that tool reentry can locally fragment the oxide line and diminish cold-lap severity, improving static strength. The fatigue performance of the stitch welds was lower than that of the strongest static condition, with short stitches particularly susceptible to notch effects due to overlap-specific features and reentry-related porosity. In general, intersecting stitch welds can surpass continuous FSW in static strength, but fatigue optimization will require mitigating the severity of the cold lap and reentry imperfections, for example, through adapted tool and pin designs.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100363"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145614593","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":"Exploring the hybridization of wire-arc additive manufacturing and resistance spot welding","authors":"Maria R.F. Barros ,&nbsp;Pedro M.S. Rosado ,&nbsp;Rui F.V. Sampaio ,&nbsp;João P.M. Pragana ,&nbsp;Ivo M.F. Bragança ,&nbsp;Carlos M.A. Silva ,&nbsp;Paulo A.F. Martins","doi":"10.1016/j.jajp.2025.100354","DOIUrl":"10.1016/j.jajp.2025.100354","url":null,"abstract":"<div><div>This paper explores a new hybrid manufacturing approach that combines wire-arc additive manufacturing (WAAM) with resistance spot welding (RSW). The approach integrates additively deposited materials with commercial sheets, which can serve as either supporting or functional elements. Experimental testing and finite element modelling allowed defining the weld lobe and optimizing key parameters such as electric current and welding time. Optimization was based on nugget shape, microstructure, and mechanical performance from destructive shear and peel tests. Two distinct joining modes were identified: symmetric and asymmetric weld nuggets, with the former exhibiting higher strength but requiring a higher heat input. A proof-of-concept prototype was developed to demonstrate the potential of this innovative hybrid manufacturing approach, combining WAAM, machining, forming, and RSW to fabricate complex, multi-thickness components with improved structural integrity.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100354"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145324211","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 tool material on joint quality in friction stir welding of aluminum-steel tailor welded blanks","authors":"Robin Göbel,&nbsp;Maximilian Keppler,&nbsp;Stefan Weihe,&nbsp;Martin Werz","doi":"10.1016/j.jajp.2025.100355","DOIUrl":"10.1016/j.jajp.2025.100355","url":null,"abstract":"<div><div>Friction stir welding (FSW) enables high-strength joints between dissimilar materials such as aluminum and steel and is particularly suited for hybrid tailor welded blanks in deep drawing. A special joining configuration, developed at the Material Testing Institute in Stuttgart, allows joining a high-strength aluminum alloy to thinner steel in a combined butt and overlap joint. Despite its proven advantages, this welding process shows inconsistent outcomes regarding formability and joint strength. This research examines the influence of tool material on weld quality and process robustness. H13 steel, ceramics (Si<span><math><msub><mrow></mrow><mrow><mn>3</mn></mrow></msub></math></span>N<span><math><msub><mrow></mrow><mrow><mn>4</mn></mrow></msub></math></span> and SiAlON) and TiAlN-coated tungsten carbide tools were evaluated in welds joining 1 mm steel to 2 mm aluminum sheets. Material accumulation was quantified by 3D scanning and continuous weighing. Weld seam integrity was assessed by X-ray imaging, metallography and tensile testing with regard to aluminum-steel intermixing. The findings show that during friction stir welding of aluminum and steel in a combined butt and overlap joint, both steel and ceramic tools predominantly degrade through the adhesion of workpiece material. The H13 tool exhibits steel/aluminum buildup detaching after 1.5-2.5 m, altering geometry and intermixing. Fluctuations in material accretion lead to varying process conditions over successive welds or even within one weld. By contrast, the TiAlN-coated WC tool exhibits significantly less buildup and therefore more uniform weld seam quality. Moreover, a relatively high degree of aluminum-steel intermixing consistently correlates with superior weld strength and formability. The study highlights how tool degradation and intermixing affect weld quality and emphasizes the role of tool materials for robust industrial applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100355"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145519440","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":"The effect of heat input on the residual stress distribution in gas-metal arc welding of carbon steel: Simulation and experimental methods","authors":"Amir Dadkhah ,&nbsp;Mahmoud Sarkari Khorrami ,&nbsp;Seyed Farshid Kashani-Bozorg ,&nbsp;Reza Miresmaeili","doi":"10.1016/j.jajp.2025.100333","DOIUrl":"10.1016/j.jajp.2025.100333","url":null,"abstract":"<div><div>A major challenge in fusion welding is the development of residual stresses and distortions, stemming primarily from non-uniform thermal cycles during welding. These stresses adversely influence fatigue life, corrosion resistance, and dimensional stability of engineering components. Heat input is a crucial parameter governing residual stress formation. Conventional experimental methods for residual stress determination are often time-consuming or destructive, making simulation an efficient alternative for stress prediction. This study assessed the effect of heat input on residual stress in the gas metal arc welding (GMAW) process through integrated simulation and hole-drilling measurements. For this purpose, A516 Gr70 steel plates were welded using the GMAW technique with varying heat inputs, both with and without a back welding. After characterizing microstructure and mechanical properties, residual stresses were quantified via the hole-drilling method. Numerical simulation employed Abaqus with the Goldak double-ellipsoid heat source model and element birth-and-death technique, with results validated against experimental data. The microhardness value of the weld zone produced by the lowest heat input was found to be ∼198 HV, with a microstructure dominated by pearlite and varying morphologies of ferrites. Simulation revealed peak residual stresses in the heat-affected zone (HAZ) and weld center across all heat inputs. The reduction in heat input and applying the back welding resulted in less tensile residual stresses in most areas and slightly increased compressive residual stresses in areas farther from the HAZ. Four-channel thermocouple measurements and numerical simulation provided detailed thermal analysis during welding, with simulated residual stresses showing 96 % agreement with hole-drilling results, validating both methodologies.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100333"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144723658","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":"Modeling and simulation of inertia and continuous drive friction welding of AISI 1215 steel","authors":"Carina Vauderwange ,&nbsp;Dirk Lindenau ,&nbsp;Heinz Palkowski ,&nbsp;Hadi Mozaffari Jovein","doi":"10.1016/j.jajp.2025.100360","DOIUrl":"10.1016/j.jajp.2025.100360","url":null,"abstract":"<div><div>To accurately simulate rotary friction welding (RFW), calibration of the material model and friction conditions is essential. This study focuses on developing a material model and simulation for RFW of AISI 1215 free-machining steel in the environment “virtua RFW”. Inertia (IFW) and continuous drive friction welding (CDFW) were physically performed with comparable energy inputs to calibrate the simulation. The aim of this study is to examine the calibration procedure in detail and subsequently perform a simulation-based process comparison of IFW and CDFW. For calibration, four material and friction factors were varied in an L16 Taguchi array. Different methods for evaluating simulation quality were assessed. Upset deviation and flash angle α measurement via image processing were determined to be the most suitable methods for evaluating the alignment between simulation and real welds. Optimal simulation parameters were identified for IFW, closely matching experimental results. Due to the velocity and pressure dependence of the friction behavior, a direct transfer of parameters to CDFW was not possible, requiring adjustments and regression analysis for accurate prediction. Optimized simulations showed differences in the thermomechanical behavior: IFW exhibited a steeper temperature gradient with a minimum cooling time t8/5 of 2.5 s and a double-wedge shape in the affected zone, while CDFW showed a broader, more uniform zone with a minimum cooling time t8/5 of 3 s. These findings improve the understanding of IFW and CDFW and provide calibrated simulation models that could facilitate more efficient process development.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100360"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145681468","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":"Measurement of residual stress due to deformation caused by slight hydroforming deformation process in double-walled pipes through external pressure","authors":"Reza Mansourian,&nbsp;Masoud Mahmoodi","doi":"10.1016/j.jajp.2025.100338","DOIUrl":"10.1016/j.jajp.2025.100338","url":null,"abstract":"<div><div>In this study, the measurement of residual stress due to deformation caused by slight hydroforming deformation process in double-walled pipes through external pressure was studied. Residual stresses were measured by nanoindentation of ST52 steel/GGG70 iron double-walled pipes. The results showed that the highest compressive residual stress was created on the inner surface of the GGG70 with effective parameters of pressure of 146 tons, the temperature of 73 °C, and percentage of Al₂O₃ nanoparticles powder in fluid of 5.6 %. Repeated nanoindentation measurements on the reference (stress-free) sample showed a variation of approximately 10 %, indicating acceptable repeatability of the method. The stresses are almost uniform and the same along the length of the part, and only very slight changes are observed in the part's initial part. The stress in the outer wall is obtained at the outer surface of ∼ 502.6 MPa and the inner surface of 506.6 MPa. Considering that the yield stress of the outer wall is considered to be ∼ 500 MPa, the entire outer wall is in a plastic state but has undergone a good amount of plastic deformation. Residual stresses are initially tensile and then reach their maximum value and with increasing depth, they are converted into compressive residual stresses and then reach an equilibrium state in the base metal. With increasing depth, there is not much change in the maximum tensile residual stress.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"12 ","pages":"Article 100338"},"PeriodicalIF":4.0,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144829241","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}