Welding in the World最新文献

{"title":"Investigating numerically and experimentally the effect of martensite start temperature on the residual stresses and distortion in laser beam welded T-joints","authors":"Karthik Ravi Krishna Murthy,&nbsp;Maximilian Gamerdinger,&nbsp;Simon Olschok,&nbsp;Uwe Reisgen","doi":"10.1007/s40194-025-02171-7","DOIUrl":"10.1007/s40194-025-02171-7","url":null,"abstract":"<div><p>This study investigates the influence of martensitic start temperature on residual stress and distortion. A double-sided fully welded T-joint was fabricated by welding a high-alloy base material (1.4318) with two different filler wire combinations (G19 9, G4Si1). The temperature distribution and distortion were measured during the welding process using thermocouples and displacement transducers. The thermo-metallurgical-mechanical effect was considered when computing a numerical simulation model for a T-joint geometry. A phase transformation model was incorporated to predict martensite formation during welding, with the martensite start temperature varied as a parameter. Further, the mechanical model was developed by integrating the thermal strains, phase strains, and mechanical strains. Results from numerical simulations and experimental measurements are compared and analyzed to assess the impact of martensite start temperature on residual stresses and distortion. From the findings, it was found that, at a reduced martensitic start temperature, there was a significant reduction in residual stresses and distortion.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 11","pages":"3541 - 3551"},"PeriodicalIF":2.5,"publicationDate":"2025-09-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02171-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145230201","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Fabrication of FGM structure with gradation of stainless steel and low carbon steel using twin wire arc additive manufacturing","authors":"Md Sajid Hussain,&nbsp;Kumari Bimla Mardi,&nbsp;Amitava Mandal","doi":"10.1007/s40194-025-02167-3","DOIUrl":"10.1007/s40194-025-02167-3","url":null,"abstract":"<div><p>Twin wire arc additive manufacturing (T-WAAM) offers the capability to fabricate functionally graded material (FGM) tailoring in a variation of compositional elements and the related properties. In this context, two feedstocks, SS 316L (SS) and ER-70S6 (LCS), were used to fabricate a FGM structure using a T-WAAM setup integrated with gas-tungsten-arc-welding (GTAW) power source. The variation of elemental compositions of the fabricated structure was obtained by controlling the feed rate of the two different feedstock materials. The two extreme ends of the fabricated wall were made of pure SS and LCS, whereas the intermediate zones were fabricated by mixing 75% SS+25% LCS, 50% SS+50% LCS, and 25% SS+75% LCS. The intermixed zones exhibited complex microstructural, mechanical, and tribological phenomena. It showed duplex phase formation, i.e., austenite (FCC) and ferrite (BCC), where the microstructure varied from austenite+martensite to bainite+pearlite to polygonal ferrite. The average hardness and wear behaviour of these zones is better than that of pure SS and LCS. Maximum hardness value of 398 HV is observed at 50–50 SS and LCS mixing zone. This SS-LCS combination shows a remarkable surface durability and excellent wear resistance. The coefficient of friction, specific wear rate, and wear depth in this zone are 0.128, 0.01 × 10³ mm³/Nm and 2.687 µm, respectively. This research offers a feasible and flexible approach to fabricating FGM, tailored design, and renovation of components, where hardness and wear interaction are more prominent.\u0000</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 11","pages":"3467 - 3481"},"PeriodicalIF":2.5,"publicationDate":"2025-09-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145230188","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of the process parameters on deposition quality of Ti6Al4V titanium alloy by powder-feed underwater laser metal deposition","authors":"Xiaofeng Wan,&nbsp;Jiaqi Li,&nbsp;Jinchao Zhang,&nbsp;Tuo Shi,&nbsp;Qingqing Zhu,&nbsp;Mingfu Shu,&nbsp;Yuhang Sun,&nbsp;Qingsong Ding","doi":"10.1007/s40194-025-02160-w","DOIUrl":"10.1007/s40194-025-02160-w","url":null,"abstract":"<div><p>The powder-feed underwater laser metal deposition (ULMD) of Ti6Al4V alloy was carried out in a local dry cavity generated by a special drainage nozzle, and the influence of laser power and scanning speed on the deposition appearance and geometry characteristics of a single track was investigated. The results show that as the laser power increases, the aspect ratio and dilution rate increase. With the scanning speed increasing, the aspect ratio increases, but the dilution rate and the deposition angle decrease. A high-quality ULMD single track with a uniform appearance and no metallurgical defects is obtained at the laser power of 2.2 kW and scanning speed of 14 mm/s. In addition, a thin wall part was fabricated using the optimal process parameters. The microstructure of the deposited metal is composed of acicular martensitic <i>α</i>′ phase, and the sizes of the martensitic in the top region are finer than those of the martensitic in the middle region and bottom region.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 11","pages":"3455 - 3465"},"PeriodicalIF":2.5,"publicationDate":"2025-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145230483","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Influence of repair welding numbers on microstructure and mechanical properties of S355J2G4 steel welded joints","authors":"Xin Zhao,&nbsp;Chenghao Xie,&nbsp;Haiting Lv,&nbsp;Zhibin Yang","doi":"10.1007/s40194-025-02144-w","DOIUrl":"10.1007/s40194-025-02144-w","url":null,"abstract":"<div><p>In this study, original welds of 12 mm thick S355J2G4 steel used for railway vehicles were repaired through Metal Active Gas (MAG) welding to determine influence of repair welding numbers on microstructure and mechanical properties of welded joints. The results indicated that the weld macrostructure did not significantly change with increasing repair welding numbers, the phase composition of the microstructure in the heat affected zone were the same while the grain size slightly increased. The microhardness values on upper weld surface between the repaired and original weld fusion lines gradually reduced as repair welding number increased. Both the average yield and tensile strengths reduced with increasing repair welding numbers, while the average elongations remained nearly constant. The tensile specimens all fractured in base metal. There were no visible cracks appeared on surface of the bending test specimen. The average impact energy and median fatigue strength both presented gradual downward trends as repair welding number increased. The fatigue specimens of the 0R (original), 1R (repaired once), and 2R (repaired twice) welded joints all fractured in weld metal, while the fatigue specimens of the 3R (repaired thrice) welded joints fractured near fusion line, this change was primarily due to the serious joint softening as repair welding number increased. The above results indicated that the microstructure and mechanical properties of the repair-welded joints still could meet the application requirements even the repair welding number reached up to three, which could provide practical guidance for developing repair strategies in industrial applications.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 10","pages":"3165 - 3176"},"PeriodicalIF":2.5,"publicationDate":"2025-08-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145062174","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"In-service and repair welding of pressurized hydrogen pipelines–a review on current challenges and strategies","authors":"Kjell Erxleben,&nbsp;Sebastian Kaiser,&nbsp;Michael Rhode,&nbsp;Thomas Kannengiesser,&nbsp;Arne Kromm","doi":"10.1007/s40194-025-02127-x","DOIUrl":"10.1007/s40194-025-02127-x","url":null,"abstract":"<div><p>Hydrogen is the energy carrier for a sustainable future without fossil fuels. As this requires a reliable transportation infrastructure, the conversion of existing natural gas (NG) grids is an essential part of the worldwide individual national hydrogen strategies, in addition to newly erected pipelines. In view of the known effect of hydrogen embrittlement, the compatibility of the materials already in use (typically low-alloy steels in a wide range of strengths and thicknesses) must be investigated. Initial comprehensive studies on the hydrogen compatibility of pipeline materials indicate that these materials can be used to a certain extent. Nevertheless, the material compatibility for hydrogen service is currently of great importance. However, pipelines require frequent maintenance and repair work. In some cases, it is necessary to carry out welding work on pipelines while they are under pressure, e.g., the well-known tapping of NG grids. This in-service welding brings additional challenges for hydrogen operations in terms of additional hydrogen absorption during welding and material compatibility. The challenge can be roughly divided into two parts: (1) the possible austenitization of the inner piping material exposed to hydrogen, which can lead to additional hydrogen absorption, and (2) the welding itself causes an increased temperature range. Both lead to a significantly increased hydrogen solubility in the respective materials compared to room temperature. In that connection, the knowledge on hot tapping on hydrogen pipelines is rare so far due to the missing service experiences. Fundamental experimental investigations are required to investigate the possible transferability of the state-of-the-art concepts from NG to hydrogen pipeline grids. This is necessary to ensure that no critical material degradation occurs due to the potentially increased hydrogen uptake. For this reason, the paper introduces the state of the art in pipeline hot tapping, encompassing current research projects and their individual solution strategies for the problems that may arise for future hydrogen service. Methods of material testing, their limitations, and possible solutions will be presented and discussed.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 10","pages":"3141 - 3164"},"PeriodicalIF":2.5,"publicationDate":"2025-08-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02127-x.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145062245","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A comprehensive review of laser marking: an in-depth exploration of processes, methods, parameters, materials, and applications","authors":"Parisa Khatami,&nbsp;Seyedeh Fatemeh Nabavi,&nbsp;Anooshiravan Farshidianfar","doi":"10.1007/s40194-025-02129-9","DOIUrl":"10.1007/s40194-025-02129-9","url":null,"abstract":"<div><p>Laser marking has evolved into a vital tool for industrial identification, ensuring traceability and combating counterfeiting with its precision and efficiency. This study delves into fiber laser marking, offering insights into its advantages, applications, and monitoring mechanisms like advanced control systems. Detailed analysis of laser marking methods aids manufacturers in selecting optimal solutions. Critical factors such as parameters and material choices are highlighted for optimizing practices in industrial applications. Additionally, the study explores laser color marking, enhancing industrial markings aesthetically. Integration of Artificial Neural Networks with RGB image processing represents a significant advancement, showcasing the study’s pioneering spirit. These findings underscore laser marking’s crucial role in industrial operations, driving efficiency and quality while pushing the boundaries of achievable outcomes in marking technology.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 11","pages":"3415 - 3442"},"PeriodicalIF":2.5,"publicationDate":"2025-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145230418","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"A novel numerical simulation model for a new EB-DED additive manufacturing method: influence mechanism of the interaction between fixture and workpiece","authors":"Xi Shu,&nbsp;Guoqing Chen,&nbsp;Chunyu Wang,&nbsp;Long Wan,&nbsp;Chunju Wang,&nbsp;Lining Sun","doi":"10.1007/s40194-025-02131-1","DOIUrl":"10.1007/s40194-025-02131-1","url":null,"abstract":"<div><p>The pre-melted electron beam fabrication (PEBF) method is proposed in this paper. Numerical simulation techniques are utilized to calculate the dynamic variations in internal stress and deformation within the component during the PEBF process and its interaction with the fixture. A contact theory is incorporated. Unlike traditional rigid or purely elastic mechanical boundary conditions, our model considers the contact between the workpiece and the fixture, employing Coulomb’s friction law to address the contact issues. The penalty function method is utilized to solve the Coulomb friction problem. The deformation of the deposited material shows minimal reduction throughout the deposition process; each deposition layer contributes to an increase in the deformation at the end of the first layer, although the increment of deformation gradually decreases. During the deposition, the interaction between the fixture and the substrate affects the deformation of the deposited material, with the lateral expansion of the substrate resulting in a reduction in the vertical deformation of the deposited structure. Temperature field analysis indicates that, except for the first layer, the cooling rate variation for subsequent layers does not exceed 15%, suggesting that multiple thermal cycles during additive manufacturing have a minimal impact on the stress and deformation of the existing deposited material.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 11","pages":"3443 - 3453"},"PeriodicalIF":2.5,"publicationDate":"2025-07-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145230417","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Surface flatness measurement of large-size weld beads based on the machine vision system and deep learning technology","authors":"Mengsi Zhang,&nbsp;Guofu Lian,&nbsp;Xianfeng Gao,&nbsp;Lei Wang,&nbsp;Bin Luo","doi":"10.1007/s40194-025-02101-7","DOIUrl":"10.1007/s40194-025-02101-7","url":null,"abstract":"<div><p>The surface flatness of traditional large-size weld beads was measured by cutting the weld area of the workpiece, then manually calculating the ratio of weld width to reinforcement height, which was time-consuming and inaccurate. This work combined a machine vision system with deep learning technology to reduce calculation errors and improve adaptability. A new network model, UG-Net, was proposed for analyzing laser stripe images of weld beads in complex backgrounds, achieving 93.69% mean intersection over union (mIoU). The Steger algorithm was used to extract the centerline from the identified laser stripes, which was segmented into feature and baseline sections. The feature section underwent cubic spline curve interpolation, while the baseline section was processed using straight-line fitting based on random sample consensus. The feature curve of the weld bead was derived to obtain extreme points. The 3D coordinates of extreme points and corresponding feature points on the baseline were determined using structured light triangulation. Finally, the difference between the feature points on the baseline and the extreme points was calculated to obtain the maximum and minimum weld bead heights, representing the surface flatness. Testing three sample sets with different welding parameters, the relative errors between the proposed algorithm’s results, and manual measurements following wire-electrode cutting were 1.132, 1.067, and 1.039%, respectively. These results proved the reliability of the proposed algorithm and introduced a new approach for fast and accurate measurement of large-size weld beads’ surface flatness. </p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 11","pages":"3371 - 3386"},"PeriodicalIF":2.5,"publicationDate":"2025-07-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145230345","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Design of experiments approach in directed energy deposition-arc with metals: optimization in pressure tank production","authors":"Tansu Göynük,&nbsp;Yiğit Hergül,&nbsp;Gökhan Can,&nbsp;Murat Yücel,&nbsp;Ulas Yaman","doi":"10.1007/s40194-025-02122-2","DOIUrl":"10.1007/s40194-025-02122-2","url":null,"abstract":"<div><p>Directed energy deposition-arc with metals (DED-ARC/M) is gaining popularity in aerospace applications due to its cost-reduction potential and shorter lead times. A notable example of expensive products manufactured traditionally is pressure tanks with oval shapes. These parts are roughly machined from bulk material and then reduced to their final thickness. By employing DED-ARC technology, material waste and CNC machining time can be minimized, leading to a significant reduction in overall part costs. This paper focuses on the design of experiments (DoE) for optimizing welding parameters to manufacture a pressure tank for aerospace applications using 17–4 PH stainless steel. To meet the high-quality and lightweight requirements of aerospace applications, it is crucial to set the welding parameters correctly. The presented DoE consists of three stages. Initially, a number of single beads with distinct parameters are deposited for a layer height of 2–3 mm. Through geometric macro inspection, most of the single-bead parameters are eliminated. Using the remaining parameter sets, flat walls are manufactured, and the specimens are taken from these walls to assess their mechanical properties. Finally, the parameter sets that yield the highest mechanical quality are employed in the additive manufacturing of the pressure tank for aerospace applications.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 11","pages":"3387 - 3402"},"PeriodicalIF":2.5,"publicationDate":"2025-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145230237","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Grain-boundary refinement in wire-arc directed energy deposition of duplex stainless steel via in-process ultrasonic vibration","authors":"Antoine Queguineur,&nbsp;Olli Wiikinkoski,&nbsp;Mohammad Hallaji,&nbsp;Gaurav Mohanty,&nbsp;Jean-Yves Hascoët,&nbsp;Iñigo Flores Ituarte","doi":"10.1007/s40194-025-02123-1","DOIUrl":"10.1007/s40194-025-02123-1","url":null,"abstract":"<div><p>Wire-arc directed energy deposition (WA-DED) is the subject of extensive research in metal additive manufacturing (AM). This study investigates the influence of ultrasonic vibration (UV) on the material properties of deposited ER2209 duplex stainless steel filler wire and evaluates the effects of UV treatment on walls fabricated both with and without weaving. The results demonstrate the effectiveness of a specially developed UV table prototype, showing clear impacts on grain size and ferrite content in the deposited samples. UV treatment reduces the primary ferrite grain width and enhances phase distribution homogeneity, potentially influencing the ferrite-to-austenite transformation during successive reheating cycles. Although the effects on surface morphology and hardness were minimal, significant microstructural changes occurred within the deposited material. UV-induced grain refinement modifies the austenite content, revealing a beneficial interaction between vibration and phase evolution. The UV table design provides a valuable foundation for reproducibility; nevertheless, further optimization of the setup is required to improve performance and support its integration into advanced industrial applications.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 11","pages":"3403 - 3413"},"PeriodicalIF":2.5,"publicationDate":"2025-07-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02123-1.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145230534","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":4,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}