Journal of Advanced Joining Processes最新文献

{"title":"Mechanical properties and microstructure of the C70600 copper-nickel alloy and C46500 brass joint using brazing technique","authors":"Hesam Mehdikhani ,&nbsp;Amir Mostafapour ,&nbsp;Behzad Binesh","doi":"10.1016/j.jajp.2025.100294","DOIUrl":"10.1016/j.jajp.2025.100294","url":null,"abstract":"<div><div>Naval brass (C46500), due to the presence of tin in this alloy, it exhibits high resistance to atmospheric and aqueous corrosion. This type of brass is widely used in various industries, including marine applications, electrical components, etc. The C70600 copper-nickel alloy, due to the formation of a solid solution, maintains high ductility while increasing tensile strength. High resistance to seawater corrosion, attributed to significant amounts of manganese and iron, are among the key characteristics of this alloy. The joining of these alloys in marine applications are required. Considering the formation of solid solutions and intermetallic compounds and their impact on mechanical properties, controlling their amounts is crucial for achieving optimal results. Brazing is known as an effective method to join these base materials. Since temperature and time are two critical parameters in brazing, influencing the formation of precipitates, this study focuses on optimizing these conditions to achieve desirable microstructural and mechanical properties. The brazing process was performed under 16 different conditions including 650, 680, 710, and 740 °C for 1, 5, 15, and 30 mins. To study the microstructure of joints, and the related phase transformations in the joint region, optical microscopy, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) were used. Mechanical properties of the samples were evaluated through strength testing and micro hardness measurements. The results indicate that with increasing temperature and duration of the joining process, the width of the thermally solidified zone decreases due to the increased diffusion rate, while the width of the isothermal solidification zone increases. Moreover, increasing the brazing time promotes phase segregation. The highest strength, measured at 106.4 MPa, was achieved for the sample joined at 710 °C for 15 mins, with the fracture surface displaying a mixed ductile-brittle mode.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100294"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143387546","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":"Enhancement of mechanical properties of thermite heat assisted friction stir welded aluminium bronze alloy (C95300) by eliminating tunnel defect","authors":"Tamil Prabakaran S ,&nbsp;Sudha J ,&nbsp;Siva S ,&nbsp;Balamurali Duraivel ,&nbsp;Vivekananda A S","doi":"10.1016/j.jajp.2025.100317","DOIUrl":"10.1016/j.jajp.2025.100317","url":null,"abstract":"<div><div>Thermite Heat-Assisted Friction Stir Welding (THAFSW) is recognized as an efficient welding method for joining aluminium bronze (AB) alloys. The mechanical and metallurgical characteristics of the welded joints were analyzed and compared with those fabricated using the conventional friction stir welding (CFSW) technique. Tensile strength and hardness assessments of the welded specimens were conducted at ambient temperature. The findings revealed that the THAFSW joints exhibited superior mechanical properties, with tensile strength and elongation improving by 11 % and 25 %, respectively, compared to joints produced through the conventional approach. The strengthening mechanism of the welded joints was examined based on images captured through macroscopy, optical microscopy, scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The THAFSW process effectively eliminated tunnel defects and facilitated the development of a uniform α-phase microstructure, which contributed to enhanced mechanical performance.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100317"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144189935","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":"Temperature influence on the repair of a hardfacing coating using laser metal deposition and assessment of the repair innocuity","authors":"Wilfried Pacquentin ,&nbsp;Pierre Wident ,&nbsp;Jérôme Varlet ,&nbsp;Thomas Cailloux ,&nbsp;Hicham Maskrot","doi":"10.1016/j.jajp.2025.100284","DOIUrl":"10.1016/j.jajp.2025.100284","url":null,"abstract":"<div><div>Additive manufacturing (AM) is a proven time- and cost-effective method for repairing parts locally damaged after e.g. repetitive friction wear or corrosion. Repairing a hardfacing coating using AM technologies presents however several simultaneous challenges arising from the complex geometry and a high probability of crack formation due to process-induced stress. We address the repair of a cobalt-based Stellite™ 6 hardfacing coating on an AISI 316L substrate performed using Laser Powder Directed Energy Deposition (LP-DED) and investigate the influence of key process features and parameters. We describe our process which successfully prevents crack formation both during and after the repair, highlighting the design of the preliminary part machining phase, induction heating of an extended part volume during the laser repair phase and the optimal scanning strategy. Local characterization using non-destructive testing, Vickers hardness measurements and microstructural examinations by scanning electron microscopy (SEM) show an excellent metallurgical quality of the repair and its interface with the original part. In addition, we introduce an innovative process qualification test assessing the repair quality and innocuity, which is based on the global response to induced cracks and probes the absence of crack attraction by the repair (ACAR<span><span>¹</span></span>). Here this ACAR test reveals a slight difference in mechanical behavior between the repair and the original coating which motivates further work to eventually make the repair imperceptible.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100284"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133080","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":"Neutron diffraction analysis of residual stress distribution in the lubricant-free TR-AFSD AA7075 repair coupled with SPH simulations","authors":"Ning Zhu ,&nbsp;Trevor Hickok ,&nbsp;Kirk A. Fraser ,&nbsp;Dunji Yu ,&nbsp;Yan Chen ,&nbsp;Ke An ,&nbsp;Luke N. Brewer ,&nbsp;Paul G. Allison ,&nbsp;J. Brian Jordon","doi":"10.1016/j.jajp.2025.100283","DOIUrl":"10.1016/j.jajp.2025.100283","url":null,"abstract":"<div><div>This work examines the residual stress in high-strength aluminum alloy repaired by lubricant-free additive friction stir deposition (AFSD) using the same aluminum alloy feedstock. Specifically, a milled groove in an AA7075-T651 substrate was repaired using the twin rod additive friction stir deposition (TR-AFSD) without using any graphite lubricant on the feedstock materials, which is required for conventional square feedstock AFSD. Residual stress distribution in the repaired substrate at different depths was quantified via neutron diffraction, where the distribution of longitudinal residual stress in the TR-AFSD repair was found comparable to materials subjected to other friction-based processes, with an M-shaped or bell-shaped distribution. The tensile longitudinal residual stress, with a peak of 171.3 MPa, spanned the center region around 36 mm, while compressive longitudinal residual stresses, ranging between -112.9 MPa and -12.3 MPa, were balanced outside the center at both the advancing side and retreating sides. The transverse and normal residual stresses were consistent across the repair, with smaller magnitudes between -52 MPa and 68.3 MPa. The non-destructive and high penetration depth nature of the neutron diffraction method enabled the calculation of von Mises stress by interpreting the three measured orthogonal residual stresses as the principal stresses. By normalizing the calculated von Mises stress to the microhardness, this quantified ratio indicates the influence of the embedded residual stresses relative to the material's strength. The higher normalized ratio observed at a deeper depth closer to the bottom of the repair, suggests that the magnitude of residual stresses is closer to the material's strength, indicating a higher potential for residual stress-induced failure at this location. We also calibrated the state-of-the-art smooth particle hydrodynamic (SPH) TR-AFSD process model to predict the von Mises stress distribution in the TR-AFSD AA7075 repair. The experimentally measured residual stress, coupled with the SPH simulation, could further help the research community to minimize the tensile region and alleviate substrate distortion in materials subjected to friction-based processes.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100283"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133071","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-brightness laser welding with beam wobbling: Achieving high-strength Al/Steel joints for battery busbars","authors":"M Chelladurai Asirvatham ,&nbsp;Iain Masters ,&nbsp;Geoff West ,&nbsp;Paul Haney","doi":"10.1016/j.jajp.2025.100305","DOIUrl":"10.1016/j.jajp.2025.100305","url":null,"abstract":"<div><div>Laser welding of aluminium tabs to nickel-plated interstitial-free (IF) steel was investigated using a high-brightness, single-mode laser with beam wobbling. The influence of interaction time, controlled by wobble amplitude and traverse speed, regulating energy distribution on weld microstructure and mechanical properties was systematically studied. Short interaction times (&lt;25 µs) and large inter-wobble distances (&gt;150 µm) minimized intermetallic compound (IMC) formation and maximized weld strength. Optimizing these parameters (wider wobble amplitudes of 0.6–0.8 mm and faster speeds of 75–100 mm/s) suppressed IMC-induced cracking, resulting in microstructures containing Fe-rich IMCs and Al-Fe₄Al₁₃ eutectic phases. Conversely, lower wobble amplitudes (&lt;0.6 mm) and slower speeds (50–75 mm/s) promoted crack-prone Al-rich Fe₂Al₅ phases. Optimized welds exhibited excellent fatigue performance, withstanding 1 million cycles at 175 N, demonstrating the potential for using lighter, cost-effective aluminium busbars in battery interconnect applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100305"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143899316","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The effect of laser welding parameters on mechanical properties and microstructure evolution of multi-layered 6061 aluminum alloy","authors":"Shoeib Karami ,&nbsp;Mohammad Yousefieh ,&nbsp;Homam Naffakh-Moosavy","doi":"10.1016/j.jajp.2024.100275","DOIUrl":"10.1016/j.jajp.2024.100275","url":null,"abstract":"<div><div>In this study, the key findings of evaluating laser beam welding parameters on the multi-layered structure of 6061 aluminum alloys fabricating by accumulative roll bonding process are reported, considering fostering mechanical properties concerning the influence of filler metal and welding speed on the weld bead quality by taking into account reducing welding defects. Welding defects, including porosity and hot cracks, formed due to the evaporation of low-molten elements such as Mg, which can be reduced by adding filler metal to compensate for the vaporized Mg content. The optimal tensile strength is related to the laser beam welding using filler metal at the speed of 40 mm/s. Work-hardening behavior leading to fatigue life improvement is associated with the rearrangement and multiplication of dislocations in all samples. The related mechanisms responsible for the microstructural evolution during the cyclic deformation process were described by transmission electron microscopy observation. The fracture surface analyzed by scanning electron microscopy indicated that delamination contributing to local necking is the leading cause of fracture in accumulative roll-bonded 6061 aluminum alloy. However, the fracture morphology of laser-welded samples displays a heterogeneous distribution of equiaxed dimples along with negligible serpentine sliding, indicating a ductile fracture mode.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100275"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133038","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":"Determination of heat input impact on residual stress, microstructure and mechanical characteristics of welded ferrite-pearlite (α-P) steel joints by using taguchi optimization approach","authors":"Nagaraju Doredla,&nbsp;Senthil Kumar N","doi":"10.1016/j.jajp.2024.100278","DOIUrl":"10.1016/j.jajp.2024.100278","url":null,"abstract":"<div><div>Ferrite-Pearlite (α-P) steels like E350 steel were extensively used in pre-engineered structures like industrial warehouses, bridges, etc., owing to their special ductility property. Submerged arc welding is highly efficient in welding long-span prefabricated structures. In this paper, weld overlay and butt weld experimental investigations were performed to optimise the welding process by understanding the influence of heat input on residual stress generation, weld efficiency, microstructural and mechanical characteristics of the weld joint to match the filler wire with the base material characteristics. Trail runs were conducted using the Taguchi design optimisation approach. Taguchi method is useful to standardise and simplify the use of design of experiments. The weld quality was evaluated using non-destructive evaluations. Residual stress was tensile near the weld and transitioned to compressive further from the root. The intensity of residual stress decreased gradually with an increase in transverse distance from the weld root. Acicular ferrite, polygonal ferrite, and traces of lath bainite microstructure were observed in the weld zone. The weld microstructure became coarser toward the melting boundary of the welded joint with an increase in heat input greater than 1.09 kJ/mm. A notable decrease in weld brittleness was observed with an increase in heat input from 1.09–1.37 kJ/mm, and the fracture initiated away from the weld with ductile and quasi-ductile cleavages. The overall microstructure and mechanical characteristics of the welded joint were improved at a controlled heat input of 1.09–1.37 kJ/mm.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100278"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133039","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":"Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding","authors":"Sungyo Jung ,&nbsp;Gi Taek Oh ,&nbsp;Seungjin Jung ,&nbsp;Chungsik Yoon","doi":"10.1016/j.jajp.2025.100311","DOIUrl":"10.1016/j.jajp.2025.100311","url":null,"abstract":"<div><div>Flux-cored arc welding (FCAW) generates hazardous byproducts such as welding fumes and hexavalent chromium (Cr(VI)), posing significant health and environmental risks. This study investigated the effectiveness of modifying specific flux components in flux-cored wires (FCWs) to reduce these emissions. One base FCW and ten flux-modified FCWs were tested under controlled conditions, capturing emissions for gravimetric and Cr(VI) analysis. Flux compositions were determined using X-ray fluorescence. Statistical analyses, including difference tests, correlation, and multiple linear regression, were conducted to evaluate the association between the content of flux components and emission rates. Sodium (Na) content in the flux was positively associated with increased emission of welding fumes and Cr(VI), while titanium (Ti) content showed a negative association. Increasing the contents of fluorine (F), potassium (K), and chromium (Cr) in the flux raised welding fume emission but reduced Cr(VI) emissions. Strategic adjustments in flux composition, specifically increasing Ti, silicon (Si) and zirconium (Zr) while decreasing Cr, K, Na, and F content, significantly reduced welding fume emissions by up to 32.4 % and Cr(VI) emissions by 95.4 %. These findings suggest that tailoring flux composition can effectively mitigate occupational and environmental hazards, enhance welder safety, and promote more sustainable FCAW practices without compromising welding performance.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100311"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144090419","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Robotized hardfacing on high-strength steels: determination of impact properties with different heat inputs","authors":"Ákos Meilinger,&nbsp;Gábor Terdik","doi":"10.1016/j.jajp.2025.100314","DOIUrl":"10.1016/j.jajp.2025.100314","url":null,"abstract":"<div><div>The use of high-strength steels as a substrate for hardfacing is becoming increasingly common in the industry (e.g., for demolition shears). In the case of joint welding, the weldability of these steels is limited because welding heat has significant affect to the base material. Both softening and hardening can occur in the different sub-zones of heat-affected zone, leading to changes in impact properties. For demolition shears, impact stresses are the most critical loads. Heat input can alter the microstructure of the heat-affected zone, potentially reducing the load-bearing capacity due to the penetration depth of the hardface layer or the buffer layer. Robotization of hardfacing creates equal layers with high precision, which helps the precise comparison. In this study, S690QL and S960QL substrates were investigated under different heat inputs, and the impact properties of these specimens were tested. Instrumented impact test results were analyzed and supplemented with surface fractography. The impact resistance of the S690QL substrate decreases with higher heat input and penetration depth. In contrast, S960QL exhibits different behavior: the use of lowest heat input causes a 226 % increase in impact energy compared with the base material. The underlying reasons for this were identified through force-time curve analysis, where the positive effect of the heat-affected zone is determined. Additionally, the maximum impact forces display different behavior for the two materials: S960QL shows higher impact force except in case of highest heat input, where the S690QL shows better force. These findings are valuable for selecting the appropriate substrate and hardfacing technology for this application and its specific loading conditions.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100314"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144124951","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancing mechanical properties and isotropy in ultrasonic assisted powder bed fusion of metals using a laser beam (PBF-LB/M) via Dual Exposure","authors":"Sebastian Platt ,&nbsp;Jan Wegner ,&nbsp;Arno Elspaß ,&nbsp;Hanna Schönrath ,&nbsp;Stefan Kleszczynski","doi":"10.1016/j.jajp.2025.100307","DOIUrl":"10.1016/j.jajp.2025.100307","url":null,"abstract":"<div><div>Parts produced via powder bed fusion of metal using a laser beam process often exhibit mechanical anisotropy due to the directional solidification, complicating part design. This study explores the use of ultrasonic-assistance to reduce anisotropy by promoting microstructural homogenization through increased nucleation. Specimens were fabricated using a dual exposure strategy, to avoid the challenges that arise with the in-situ ultrasonic excitation of a powder bed. Furthermore, a comprehensive microstructural as well as mechanical analysis was carried out. Microstructural analysis revealed increased grain orientation variation in ultrasonically treated specimens. Mechanical testing showed improved tensile and yield strength and reduced anisotropy, with tensile and yield strength anisotropy decreasing by 55.4 % and 46.1 %, respectively. Despite increased surface roughness, ultrasonic treatment reduced anisotropy in ductility-related properties, highlighting its potential to improve the performance of additively manufactured parts by reducing anisotropy and simultaneously enhancing mechanical properties.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100307"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143921669","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}