Journal of Advanced Joining Processes最新文献

{"title":"Controlling debond on demand performance in adhesive systems using structurally tuned expandable graphite fillers","authors":"O Kachouri,&nbsp;J Bardon,&nbsp;D Ruch,&nbsp;A Laachachi","doi":"10.1016/j.jajp.2025.100309","DOIUrl":"10.1016/j.jajp.2025.100309","url":null,"abstract":"<div><div>The emergence of debonding technologies has enabled adhesive systems to better align with the principles of sustainability and the circular economy by addressing the gap between the end-of-life stage of adhesively bonded products and the potential for component reuse. In this context, the present study explores the application of thermally responsive additives to induce controlled debonding in adhesive joints. In our previous investigations, it was shown that integrating various types of flame retardants (intumescent and non-intumescent) significantly reduced the debonding temperature, by altering the thermomechanical properties of the joint at temperatures substantially lower than the degradation onset of the unmodified adhesive system. Expandable graphite (EG), a thermally responsive material, has previously been employed with success for similar purposes. Its incorporation into the adhesive layer, even in trace amounts, results in a very significant expansion upon the application of heat, thereby providing an effective mechanism for disassembling adhesively bonded structural assemblies. The present study builds on this prior research and probes deeper into the manufacturing processes underlying EG. The primary hypothesis explored is whether tailoring these processes can result in modulating the thermal response of adhesives modified by EG, thereby achieving debonding at distinct temperature ranges suitable for a wide spectrum of applications. This study investigates EG-modified adhesives, assessing their mechanical properties, thermomechanical degradation, and microstructural changes using characterization techniques such as pull-off tests, microtomography, TGA, and DMA. Finally, the recycling potential is demonstrated through the successful reuse of debonded substrates after a simple cleaning process.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100309"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144124952","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":"Direct bonding mechanism of titanium and PET resin via heating and pressurization: Influence of bubble dynamics on bonding strength","authors":"Katsuyoshi Kondoh ,&nbsp;Nodoka Nishimura ,&nbsp;Kazuki Shitara ,&nbsp;Shota Kariya ,&nbsp;Ke Chen ,&nbsp;Junko Umeda","doi":"10.1016/j.jajp.2025.100301","DOIUrl":"10.1016/j.jajp.2025.100301","url":null,"abstract":"<div><div>In response to growing environmental concerns, the transportation industry, including automotive and aerospace sectors, has emphasized improving fuel efficiency and reducing carbon dioxide emissions. To achieve significant weight reduction, multi-material design strategies that strategically utilize different materials based on their properties are being adopted. This trend highlights the need for advanced joining technologies capable of bonding dissimilar materials, such as metals and polymers or resins, while maintaining structural integrity and lightweight performance. This study investigates the direct bonding mechanism between pure titanium (Ti) and polyethylene terephthalate (PET) resin using a simple heating and pressurization process. Bubble formation at the bonding interface, a critical factor influencing joint strength, was analyzed through in-situ observation. Results show that controlled bubble dynamics enhance bonding by creating localized pressure, while excessive bubbles act as defects. Optimal bonding conditions were identified at 200–300 °C with relatively high bonding shear stress. X-ray photoelectron spectroscopy revealed the formation of Ti-C bonds, confirming strong chemical interactions at the interface. Additionally, pyrolysis gas chromatography-mass spectrometry identified ethylene glycol as a key component in bubble generation during thermal decomposition of PET. The findings highlight the significance of surface preparation, thermal control, and bubble management in achieving high bonding strength. This research provides insights into sustainable and efficient methods of dissimilar materials that can improve recyclability and support the development of advanced lightweight structures.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100301"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143738514","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":"Thermo-mechanical and material flow characteristics of tool sequencing dynamics in refill FSSW of thin alclad AA7075-T6 sheets: Numerical analysis using meshless smoothed-particle hydrodynamics method","authors":"Venkata Somi Reddy Janga,&nbsp;Mokhtar Awang,&nbsp;Nabihah Sallih,&nbsp;Tamiru Alemu Lemma","doi":"10.1016/j.jajp.2025.100285","DOIUrl":"10.1016/j.jajp.2025.100285","url":null,"abstract":"<div><div>This study is focused on improving the joint strength of AA7075-T6 specimens with aluminium cladding (alclad) joined through the refill friction stir spot welding (RFSSW) process. The bonding ligament weakens the RFSSW joint because the alclad layer is trapped between the specimens. This layer hinders material mixing during welding and creates a weak interface prone to crack initiation and propagation during external loading, affecting joint integrity. To overcome this problem, a novel tool sequencing variant of RFSSW, the pin plunging reinforced RFSSW (PPRSP-RFSSW), is proposed. A smoothed-particle hydrodynamics (SPH) formulation-based 3D thermo-mechanical model is developed to study the thermo-mechanical and material flow properties as it is possible to trace the field variables explicitly; it can manage significant material/elemental deformations and capture material mixing dynamically. The PPRSP-RFSSW is numerically analyzed and compared to existing sleeve plunging RFSSW (SP-RFSSW). The numerical model's accuracy was tested by comparing temperatures to experimental temperature data in published papers, and the results corresponded well. Comparisons are made between the SP-RFSSW and PPRSP-RFSSW concerning their heat distribution, plasticization, and material flow. Enhanced material mixing and plasticization were observed through PPRSP-RFSSW, and this tool sequencing is recommended for joining alclad AA7075-T6 specimens.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100285"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133079","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancing the weld quality of polyetheretherketone polymer cylinders using reducing pores in the weld interface","authors":"Chil-Chyuan Kuo ,&nbsp;Xiao-Ze Xie ,&nbsp;Chong-Xu Liao ,&nbsp;Wen-Bin Huang ,&nbsp;Yu-Jie Chen ,&nbsp;Armaan Farooqui ,&nbsp;Song-Hua Huang ,&nbsp;Shih-Feng Tseng","doi":"10.1016/j.jajp.2025.100281","DOIUrl":"10.1016/j.jajp.2025.100281","url":null,"abstract":"<div><div>Continuous drive friction welding (CDFW) is a highly efficient technique for fabricating large Polyether-ether-ketone (PEEK) components. However, the bending strength of welded specimens is often constrained by the formation of pores at the weld interface. Addressing this limitation, this study aims to enhance the bending strength of PEEK polymer cylinders by applying ultrasound-assisted continuous drive friction welding (UACDFW). To further improve joint performance, a novel post-compression technique is introduced and used after the welding process to increase the weld-bonded area. Additionally, image processing software is employed to evaluate and analyze the weld-bonded area ratio, comprehensively assessing the interfacial characteristics. Optimizing CDFW parameters increased the bending strength of the welded components from 201.6 MPa to 380.8 MPa and the joint area ratio from 77.54 % to 99.99 %. The optimized parameters include a rotational speed of 4000 rpm, a preheating time of 5 s, and a post-compression feed rate of 3.2 mm/s. The results demonstrate the potential of UACDFW and post-compression techniques as effective solutions for improving the mechanical performance and reliability of PEEK components in high-performance applications.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100281"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133072","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Investigation of microstructure and mechanical properties of austenitic steel bimetallic structures fabricated using wire arc direct energy deposition for remanufacturing applications","authors":"Rupendra Singh Tanwar,&nbsp;Suyog Jhavar","doi":"10.1016/j.jajp.2025.100287","DOIUrl":"10.1016/j.jajp.2025.100287","url":null,"abstract":"<div><div>In this work, bimetallic structures of two austenitic steels (SS316L and SS309) were fabricated using wire arc Direct Energy Deposition (DED). The fabrication process involved in the strategy of SS316L-SS309-SS316L on an SS316L substrate sequentially. Each material deposited 10 layers to one over another and forming two interfaces. Subsequently, the microstructure and mechanical properties, were evaluated in the deposited materials and at their interface. The microstructure predominantly consisted of the austenitic (γ) phase with a minimal amount of δ-ferrite phases in both stainless steels. The elemental distribution confirmed through EDS and verified by the Schaeffler diagram. SS309 exhibited a higher δ ferrite content compared to SS316L, and the interfaces showed a δ-ferrite content between the two base metals, the δ-ferrite mitigate the issue of hot cracking which occurred generally in the austenitic steels. The hardness ranged from 206 to 289 Vickers hardness (HV), with a considerable increase at the interface due to concentration of δ ferrite. The yield and ultimate tensile strengths were higher in the bimetallic samples tested in the build direction compared to the deposition direction with minimal variation indicating low anisotropy in mechanical properties. Tensile fracture results showed dimples, deep dimples, and microcracks, with failures occurring on the SS316L side. These findings demonstrate the effectiveness of the wire arc DED process in fabricating of bimetallic structure of SS316L-SS309 with improved strength.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100287"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133081","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":"Role of zinc coating on joint properties in impact spot welded Al 6111 aluminum alloy to galvanized high-strength low-alloy steel","authors":"Angshuman Kapil ,&nbsp;Anupam Vivek ,&nbsp;Glenn Daehn","doi":"10.1016/j.jajp.2024.100276","DOIUrl":"10.1016/j.jajp.2024.100276","url":null,"abstract":"<div><div>This study investigates the influence of Zinc (Zn) coating on the mechanical properties of impact spot welded joints between Aluminum (Al) 6111 alloy and galvanized high-strength low-alloy (HSLA) 340 steel using vaporizing foil actuator welding (VFAW). The Zn coating significantly impacts the weld interface, leading to a heterogeneous structure with regions of retained Zn and trapped jetted material. These regions inhibit direct contact between Al and steel, preventing effective metallurgical bonding and reducing joint strength by 60 % compared to uncoated steel. While the Zn coating impedes bond formation in some areas, near-complete Zn removal in other zones promotes localized ductile tearing and partial bonding, slightly mitigating the overall negative effect. Additionally, a brazing effect outside the weld zone, resulting from the jetting and solidification of Zn and Al-Zn, provides some strength to the joint. The findings highlight the complex role of Zn coating in VFAW, demonstrating that a continuous Zn layer at the weld interface is more detrimental to joint performance than discrete and thin intermetallic compounds.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100276"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143133084","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A comprehensive review on the integration of artificial intelligence in friction stir welding for monitoring, modelling, and process optimization","authors":"Mostafa Akbari ,&nbsp;Ezatollah Hassanzadeh ,&nbsp;Yaghuob Dadgar Asl ,&nbsp;Amirhossein Moghanian","doi":"10.1016/j.jajp.2025.100316","DOIUrl":"10.1016/j.jajp.2025.100316","url":null,"abstract":"<div><div>Recent advancements in artificial intelligence (AI) technologies have expanded their applications across various industrial environments, particularly in the field of Friction Stir Welding (FSW), a relatively modern manufacturing technique. AI techniques are primarily employed for modeling, monitoring, optimization, and management of complex systems influenced by multiple parameters within industrial processes. This study systematically reviews and evaluates commonly utilized AI techniques in FSW, highlighting their effectiveness, accuracy, and comparative advantages. The discussion is organized into three distinct sections, each focusing on the critical roles of AI and machine learning (ML) in FSW. The first section addresses process prediction, showcasing how AI techniques predict welding outcomes using historical data and process parameters, which enhances decision-making prior to actual implementation. The second section examines process control, emphasizing how AI systems enable real-time monitoring and adaptive control of the welding process. This functionality allows for immediate parameter adjustments, thus significantly improving weld consistency and quality by minimizing defects. Lastly, the third section pertains to the optimization of FSW parameters, illustrating how AI-driven algorithms analyze complex interactions among multiple variables to determine the most effective process settings. By adopting this structured approach, the review articulates the comprehensive benefits of integrating AI into the friction stir welding process, ultimately contributing to enhanced joint quality and improved operational efficiency.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100316"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144189936","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":"Regulating intermetallic compound growth and bridging in SnAg solder under electromigration stress through Ni addition and sn crystallographic orientation-grain size","authors":"Dinh-Phuc Tran,&nbsp;Ya-Ting Xiao,&nbsp;Mai-Phuong La,&nbsp;Shi-Chi Yang,&nbsp;Chih Chen","doi":"10.1016/j.jajp.2025.100320","DOIUrl":"10.1016/j.jajp.2025.100320","url":null,"abstract":"<div><div>As semiconductor devices scale down, electromigration (EM) failures in interconnects become more severe, requiring effective under-bump metallization (UBM) strategies. Herein, we investigated EM failures correlated with the development of intermetallic compounds (IMCs) in two UBM structures (Cu/SnAg/Cu and Cu/SnAg/Ni/Cu). Results showed that the Ni layer resulted in thinner IMCs. It acted as a diffusion barrier, which effectively suppressed IMC growth. We also found that the IMC formation in both solder structures was significantly influenced by the Sn grain orientation. A lower <em>c</em>-axis angle of beta-Sn to EM flow associated with faster IMC formation. Sn grain size also impacted IMC growth, with larger grains resulting in slower IMC formation as a result of the reduced grain boundary density. In addition, the IMC bridging phenomenon was observed in the joints. It was found that IMC bridging occurred less frequently in Ni UBM solder joints compared to Cu/SnAg/Cu counterparts. Such a difference could be attributed to the lower solubility of Ni in Sn compared to Cu. The Ni served as a barrier, which limited the Ni dissolution into the Sn solder. It suppressed the IMC formation/growth, thereby reducing the IMC bridging probability in the Cu/SnAg/Ni/Cu joints.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100320"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144212411","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":"Friction stir welding of dissimilar aluminum and copper alloys: A review of strategies for enhancing joint quality","authors":"Mohamed I.A. Habba ,&nbsp;Mohamed M.Z. Ahmed","doi":"10.1016/j.jajp.2025.100293","DOIUrl":"10.1016/j.jajp.2025.100293","url":null,"abstract":"<div><div>Friction stir welding (FSW) has emerged as a promising technique for joining dissimilar aluminum (Al) and copper (Cu) alloys, which are increasingly used in various industries owing to their unique properties. However, significant differences in the physical, thermal, and mechanical properties of Al and Cu pose challenges for achieving high-quality joints. This review comprehensively examines strategies for enhancing the joint quality of FSWed Al-Cu dissimilar alloys. The microstructural evolution and intermetallic compound (IMC) formation at the Al-Cu interface during FSW are discussed in detail. The effects of process parameters, such as tool rotation speed, traverse speed, and tool geometry, on the mechanical properties and fracture behavior of the joints were analyzed. Furthermore, various strategies for improving joint quality are reviewed, including process modification through optimized tool offsetting and material positioning, ultrasonic-assisted FSW, submerged FSW, stir zone modification using interlayers and reinforcement particles, external cooling and heating techniques, and joint design optimization. The effectiveness of each strategy in refining the microstructure, suppressing detrimental IMC formation, and enhancing the mechanical properties was evaluated based on the findings of previous studies. The research demonstrates that joint quality strongly depends on the precise control of process parameters and material positioning, with tool offsets of 1–2 mm toward the aluminum side consistently producing superior results. Modern assisted techniques have shown remarkable improvements in joint performance, with ultrasonic-assisted FSW and submerged FSW enhancing the tensile strength by up to 42 % through better control of the heat input and intermetallic compound formation. This review focuses on advanced strategies aimed at overcoming these challenges, including ultrasonic-assisted FSW, submerged FSW, and innovative interlayer techniques. Additionally, the review provides a comprehensive analysis of recent developments in process optimization, microstructural refinement, and mechanical property enhancement to achieve high-quality Al-Cu joints and offers guidance for selecting appropriate strategies to meet specific application requirements.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100293"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143420437","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":"Aluminum surface treatment and process optimization: Boosting mechanical performance in aluminum/polypropylene composite friction stir lap joints","authors":"Mojtaba Movahedi,&nbsp;Mahtab Mohsenirad,&nbsp;Ashkaan Ozlati","doi":"10.1016/j.jajp.2025.100297","DOIUrl":"10.1016/j.jajp.2025.100297","url":null,"abstract":"<div><div>The effects of chemical surface treatment of aluminum sheet and tool rotational speed (in the range of 300–1100 rpm) were studied on the macro/microstructure and mechanical behavior of friction stir lap joints between aluminum-magnesium aluminum alloy and a polypropylene composite containing 20 wt.% talc and 10 wt.% elastomer. Macrostructural studies of the joints revealed the formation of macroscopic mechanical locks between the aluminum and polymer base sheets, characterized by aluminum pieces resembling anchors penetrating the polymer substrate. The size of the anchors decreased as the rotational speed increased, and their orientation changed from being parallel with the interface of the aluminum/composite sheets to being perpendicular, and then facing the opposite direction. The larger anchors, as well as those penetrating relatively perpendicular into the polymer composite substrate, provided the joints with the highest fracture load and absorbed energy up to peak load at the intermediate tool rotational speeds of 700 and 900 rpm. Microstructural analysis demonstrated that chemical surface treatment with a solution of HCl and FeCl₃ in distilled water significantly increased the surface roughness of the aluminum sheet (by a factor of ∼4) and created numerous microscopic voids on its surface. The molten polymer formed during welding penetrated into these voids, creating numerous microscopic mechanical locks. These locks substantially enhanced the tensile-shear performance of the joints, resulting in up to ∼80 % higher fracture load and ∼380 % higher absorbed energy compared to joints without surface treatment of the aluminum. The influence of the morphology of mechanical locks on the location and mode of joint fracture was also investigated.</div></div>","PeriodicalId":34313,"journal":{"name":"Journal of Advanced Joining Processes","volume":"11 ","pages":"Article 100297"},"PeriodicalIF":3.8,"publicationDate":"2025-06-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143526766","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}