Welding in the World最新文献

{"title":"Residual stress distribution and deformation in wire + arc additive manufactured titanium alloy: insights from simulation and cold cutting analysis","authors":"Banglong Yu,&nbsp;Ping Wang,&nbsp;Yong Liu,&nbsp;Ze Chen,&nbsp;Bin Zhang,&nbsp;Xiaoguo Song","doi":"10.1007/s40194-025-02051-0","DOIUrl":"10.1007/s40194-025-02051-0","url":null,"abstract":"<div><p>The distribution of residual stress and accurate deformation prediction in wire arc additive manufacturing (WAAM) and subsequent cutting components were crucial for practical application. This study focused on simulating titanium alloy walls manufactured by WAAM to analyze thermal and residual stress distributions. Subsequently, the blade shape of the WAAM wall was subjected to cold cutting conditions using the finite element method. The residual stress and deformation of WAAM were studied under various cutting directions. WAAM and cutting components were scanned and analyzed using the Calibry Nest scanner. The findings reveal that in the middle line of the deposition cross-section, residual compressive stress emerges after 18 layers, and the distribution of longitudinal residual stresses follows a \"tension–compression-tension\" pattern. In cutting direction from the middle to both sides, the deformation of the components is effectively controlled by a narrower residual stress range. As the number of deposition layers increases, the deformation in the width direction rises to a maximum of approximately 0.2 mm. Cold cutting alleviates thermal and residual stresses induced during the WAAM process, reducing substrate deformation.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 6","pages":"1563 - 1579"},"PeriodicalIF":2.4,"publicationDate":"2025-04-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143925433","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":"Microstructure and properties of conventional and hybrid joints of IN718 brazed with VZ2177","authors":"Lukas Wojarski,&nbsp;Julia Bültena,&nbsp;Fabian Frittgen,&nbsp;Wolfgang Tillmann","doi":"10.1007/s40194-025-02035-0","DOIUrl":"10.1007/s40194-025-02035-0","url":null,"abstract":"<div><p>Brazing hybrid joints of additively manufactured and conventionally produced components made of IN718 opens new application possibilities for additive manufacturing processes, such as PBF-LB/M, in industrial production processes. The combination of hybrid structures enables cost-effective production of large-volume parts with complex features. In this work, the differences between hybrid and conventional joints are analysed, due to the different microstructure of additive manufactured IN718 compared to bulk material. The differences in the microstructures lead to different diffusion paths of the elements from the molten braze alloy along the grain boundaries and to different wetting behaviors. This has a significant effect on the microstructure and the mechanical properties of the joints. To investigate the effect of the microstructure of PBF-LB/M base materials on the brazing of IN718 with the braze alloy VZ2177, vacuum brazing with varying dwell time has been employed to manufacture joints of the bulk material and hybrid joints, consisting of additively manufactured and bulk IN718. Due to the phosphorus in the filler metal, brittle phases in the center of the brazing zone have formed in both joint types. With increasing brazing, the width of the brazing area grew. In the hybrid joint, a strong formation of IMC phases could be observed at the PBF-LB/M side of the joint leading to a higher hardness, which was more pronounced at longer brazing times. The increase in hardness was accompanied with a crack formation that was located near the PBF-LB/M-side only in those hybrid joints with long brazing time and occurred most probably due to stress relief during cooling.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 6","pages":"1757 - 1766"},"PeriodicalIF":2.4,"publicationDate":"2025-04-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02035-0.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143925690","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":"Effects of vacuum brazing on microstructure and pseudoelasticity of NiTi shape memory alloy brazements","authors":"Lukas Wojarski,&nbsp;Alexa Nebel,&nbsp;Wolfgang Tillmann","doi":"10.1007/s40194-025-02044-z","DOIUrl":"10.1007/s40194-025-02044-z","url":null,"abstract":"<div><p>NiTi shape memory alloys exhibit pseudoelasticity, allowing them to fully recover from prior deformations under varying thermal or mechanical loads. Unlike conventional materials like steels, these alloys can endure elastic strain rates up to ten times higher, owing to a diffusion-free transformation between the austenite and martensite phases in their crystal lattice induced by temperature or stress. Given their material properties, NiTi shape memory alloys find applications as actuators, implants, and stents, demanding high reliability and biocompatibility standards. To maintain maximum pseudoelasticity when joining NiTi components, any microstructural changes have to be kept to a minimum. In this regard, vacuum brazing is a promising joining technique, as it is capable to produce joints at comparatively low joining temperatures without melting the base material. Hence, this paper is aimed at evaluating the influence of different holding times and brazing temperatures on the deformation behavior of NiTi alloys in vacuum brazing applying AgCuTi braze alloy. For this purpose, microstructural analyses by means of SEM and EDS as well as tensile tests were conducted. Furthermore, the fracture surfaces were analyzed by SEM. It could be observed that a stress plateau was present in the brazed samples leading to the assumption that brazing with AgCuTi is a suitable joining technique to preserve the properties of NiTi. Nevertheless, the brazed samples fractured in the stress plateau. </p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 6","pages":"1767 - 1774"},"PeriodicalIF":2.4,"publicationDate":"2025-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02044-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143925608","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":"TIG braze welding of rod-type art structures","authors":"Serhii Minakov,&nbsp;Yevgenia Chvertko,&nbsp;Nataliya Strelenko,&nbsp;Anton Minakov,&nbsp;Denys Stepanov,&nbsp;Anatoliy Zavdoveev,&nbsp;Dmytro Vdovychenko,&nbsp;Ivan Vdovychenko,&nbsp;Ievgen Byba","doi":"10.1007/s40194-025-02045-y","DOIUrl":"10.1007/s40194-025-02045-y","url":null,"abstract":"<div><p>The paper presents the results of research on artwork joints of considerable thickness (10 mm). Butt welds in artworks are always difficult to perform because access to the joint is often one-sided. Traditional arc welding technologies are of limited use for such one-off production tasks, as full access to the joint is required and after welding the bulge must be cleaned from all sides of the bar, which is often unacceptable. Existing brazing technologies require a controlled gap between the joining surfaces, which is impossible to achieve for a wide variety of joints in art designs. Increasing the gap results in a decrease in the mechanical properties of the structure. A synergistic combination of welding and brazing using TIG technology can ensure a high-quality joint for thick bars of art structures. For such joints and conditions, the technology of high-temperature arc (TIG) brazing with partial melting of the parts to be joined and subsequent introduction of brazing alloy (CuSi3) into the metal pools of the parts to mix the liquid metal of the parts and the brazing alloy was developed. The developed technology makes it possible to fill the gap between the surfaces of bar-type parts with one-way access in the flat position, with minimal need to clean up solder that has protruded beyond the part.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 6","pages":"1775 - 1786"},"PeriodicalIF":2.4,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02045-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143925604","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":"Effect of heat control on mechanical properties and residual stresses at the transition zone of component and substrate in hybrid DED-arc manufacturing","authors":"R. Scharf-Wildenhain,&nbsp;L. Engelking,&nbsp;A. Haelsig,&nbsp;D. Schroepfer,&nbsp;T. Kannengiesser,&nbsp;J. Hensel","doi":"10.1007/s40194-025-02036-z","DOIUrl":"10.1007/s40194-025-02036-z","url":null,"abstract":"<div><p>In hybrid additive manufacturing, components or semi-finished products manufactured by conventional primary forming are enhanced or modified by additive manufactured structures. However, systematic investigations focusing on the critical transition area between the specific properties of the substrate (like high-strength) and the additively manufactured component, made of specific filler material, are still lacking. The focus of the present study was to determine the influence of heat control on the <i>∆t</i>_8/5 cooling time, the distortion, the mechanical properties, and the residual stresses in the transition area of hybrid-additive components. This contributed to the knowledge regarding the safe avoidance of cold cracking, excessive distortion, a reduction in yield stress, and the implementation of hybrid DED-arc manufacturing. The heat control was varied by means of heat input and working temperature such that the <i>∆t</i>_8/5 cooling times corresponded to the recommended processing range. The heat input has a greater influence on the cooling time in the transition area than the working temperature. Working temperature and the total energy applied per layer have a significant effect on component distortion. The lowest working temperature of 100 °C in combination with the highest total energy per layer leads to significantly greater distortion compared to manufacturing with a high working temperature of 300 °C and low total energy per layer. In addition, the longitudinal residual compressive stresses in the sensitive transition area are reduced from − 500 MPa to approx. − 200 MPa by adjusting the working temperature from 100 to 300 °C. Such complex interactions must be clarified comprehensively to provide users with easily applicable processing recommendations and standard specifications for an economical hybrid additive manufacturing of components made, for example, of high-strength steels in the transition area.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 6","pages":"1547 - 1561"},"PeriodicalIF":2.4,"publicationDate":"2025-04-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-02036-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143925606","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":"Comprehensive optimization of In625 laser cladding: from process parameters to path parameters","authors":"Yingying Zhang,&nbsp;Jiayu Sun,&nbsp;Yiqi Wang,&nbsp;Zhengyu Sun,&nbsp;Yanchong Gao,&nbsp;Tianbiao Yu","doi":"10.1007/s40194-025-02026-1","DOIUrl":"10.1007/s40194-025-02026-1","url":null,"abstract":"<div><p>This study aims to optimize the single-track process parameters (laser power <i>P</i>, scanning speed <i>V</i>, powder feed rate <i>F</i>) and multi-track, multi-layer path parameters (overlap distance <i>L</i>, <i>Z</i>-axis increment Δ<i>Z</i>) in In625 laser cladding. The optimization objectives include clad width <i>W</i>, height <i>H</i>, melt pool area <i>S</i>, and dilution rate <i>D</i>. A Taguchi experimental design was employed, utilizing bubble plots and surface plots to visually present the influence trends of process parameters on the optimization objectives. Analysis of variance (ANOVA) and signal-to-noise ratio (S/N) analysis were conducted to assess the significance and impact of the process parameters on the optimization objectives. Using the entropy-weight TOPSIS method, the optimal parameter combination (<i>P</i> = 450W, <i>V</i> = 9 mm/s, <i>F</i> = 10.21 g/min) was determined based on the <i>C</i> value of the comprehensive evaluation index. The path parameters were optimized using a combination of theoretical analysis and experimentation to obtain the optimal overlap distance (<i>L</i> = 730 μm) and <i>Z</i>-axis increment (Δ<i>Z</i> = 180 μm). The optimized parameters were validated through multi-track, multi-layer experiments, and the results show that the fusion cladding layer prepared with the optimized parameters has a uniform and dense organization, uniform hardness distribution, small fluctuation of friction coefficient, and stable performance of the fusion cladding layer. The optimized parameters contribute to the effective implementation of multi-track, multi-layer laser cladding processes, providing a reliable foundation for surface repair and modification in practical applications.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 6","pages":"1529 - 1546"},"PeriodicalIF":2.4,"publicationDate":"2025-03-31","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143925504","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":"Microstructure and mechanical strength of the active metal brazed Si3N4/Cu joint with AgCuTi/Cu foam/AgCuTi composite filler","authors":"Ying Wang,&nbsp;Wei Feng,&nbsp;Ruizhi Zhang,&nbsp;Ruxia Liu,&nbsp;Yong Xiao,&nbsp;Guoqiang Luo,&nbsp;Qiang Shen,&nbsp;Jian Zhang","doi":"10.1007/s40194-025-02027-0","DOIUrl":"10.1007/s40194-025-02027-0","url":null,"abstract":"<div><p>AgCuTi/porous Cu foam/AgCuTi sandwich composite filler was used as the interlayer to enhance the brazing strength of the Si₃N₄/Cu joints. The typical microstructure of the joint brazed with the sandwich composite filler at 880 °C was Si₃N₄/TiN/Ti₅Si₃+CuTi/Ag(s,s)+Cu(s,s)/Cu, where Cu foam forms an array structure within the joint, creating an interpenetrating network with silver. The thickness of the TiN reaction layer increased from 0.58 to 1.28 µm when the thickness of the porous Cu foam layer increased from 100 to 300 µm. The Si₃N₄/Cu joint obtained with 300 µm porous Cu foam owned the highest shear strength of 121.7 MPa, which improved by 281% than that with the use of AgCuTi filler alone. Further, EBSD analysis and finite element simulation revealed that the reduction in residual stress and the increase in plastic deformation effect induced by the Ag(s,s)+Cu(s,s) interpenetrating network structure are the key factors for the enhancement of the mechanical properties of this Si₃N₄/Cu joint brazed with AgCuTi/porous Cu foam/AgCuTi sandwich composite filler.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 6","pages":"1743 - 1756"},"PeriodicalIF":2.4,"publicationDate":"2025-03-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143925538","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":"Wire arc additive manufacturing of 7075/5356 aluminum alloy laminated composite: Microstructure, mechanical properties and fracture mechanism","authors":"Yipeng Wang,&nbsp;Shuo Zhang,&nbsp;Hong Li,&nbsp;Erika Hodúlová,&nbsp;Zhuoxin Li","doi":"10.1007/s40194-025-02019-0","DOIUrl":"10.1007/s40194-025-02019-0","url":null,"abstract":"<div><p>A novel 7075/5356 aluminum alloy laminated composite was fabricated by alternately depositing a 7075 wire and a 5356 wire layer-by-layer using wire arc additive manufacturing (WAAM) process. The microstructure, mechanical properties, and fracture mechanism of the produced components under as-deposited and heat-treated conditions were systematically investigated. Results demonstrated that there was an interlayer formed between the 7075 layer and 5356 layer, which shows gradient changes in the number of second phases and microhardness. In comparison with single 7075 aluminum alloy components, the heat-treated 7075/5356 aluminum alloy laminated composite exhibited superior comprehensive mechanical properties. The elongation was 103.8%, 50.7% higher in vertical and horizontal directions, while the tensile strength was only 18.4% and 14.3% lower, respectively. The fracture modes of 7075 layer and 5356 layer show differences, which were intergranular fracture and intergranular-transgranular mixed fracture, respectively.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 6","pages":"1515 - 1528"},"PeriodicalIF":2.4,"publicationDate":"2025-03-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143925432","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":"Virtual reality based programming of human-like torch operation for robotic welding","authors":"Yijie Hu,&nbsp;Jun Xiao,&nbsp;Shujun Chen,&nbsp;Shengnan Gai","doi":"10.1007/s40194-025-01946-2","DOIUrl":"10.1007/s40194-025-01946-2","url":null,"abstract":"<div><p>In complex welding tasks, skilled manual welders often outperform welding robots, primarily due to their expertise in torch manipulation. To address this, a robotic welding teaching system was developed to assist welders in controlling the torch. This system utilizes human–robot interaction to track the welder's movements, significantly enhancing the welding robot's ability to handle intricate weld seams. A virtual welding robot module, created in Unity3D with virtual reality (VR) technology, closely replicates the real robot. This module is integrated with a human–robot interaction interface and a welder operation module. Motion mapping strategies were devised to transfer the welder's movements from the handle to the welding torch, including \"static\", \"dynamic\", \"velocity\" and \"acceleration\" strategies. These strategies were tested across four trajectories: linear, arc, sinusoidal, and spatial intersection curves. The results revealed the superiority of the \"dynamic\" strategy. Further evaluations of the teaching system's performance—specifically its \"trajectory accuracy\", \"trajectory delay\" and \"time delay\"—were conducted for straight lines, arcs, and flip motions. The test results showed that, within the operating speed range of 1 to 40 mm/s and 10 to 40°/s, the system's time delay is less than 0.12 s, with actual trajectory errors remaining below 0.06 mm and 0.1°. These performance metrics demonstrate that the system effectively meets the requirements for precise tracking of both the weld seam and torch manipulation.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 5","pages":"1447 - 1458"},"PeriodicalIF":2.4,"publicationDate":"2025-03-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143835702","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":"The interface structure of medical Al2O3/Ti-13Nb-13Zr diffusion-bonded joints and their electrochemical corrosion behavior in simulated body fluid","authors":"Hongwei Niu,&nbsp;Yaqian Liu,&nbsp;Hong Bian,&nbsp;Xiaoguo Song,&nbsp;Hongyun Zhao","doi":"10.1007/s40194-025-02006-5","DOIUrl":"10.1007/s40194-025-02006-5","url":null,"abstract":"<div><p>The medical Al₂O₃/Ti-13Nb-13Zr (TNZ) alloy joints were achieved by diffusion bonding at 1175 °C/60 min/3 MPa. The interfacial microstructures of the bonded joints were investigated with a scanning electron microscope (SEM), energy-dispersive spectrometer (EDS), and X-ray diffraction (XRD). The results show that the typical microstructure of the Al₂O₃/TNZ joint, which was obtained at 1175 °C for 60 min under a pressure of 3 MPa, was Al₂O₃ ceramic/TiAl layer + TiO₂ + Nb₂O₅ + AlNb₂/continuous Ti₃Al layer/acicular Ti₃Al + Ti (s,s)/TNZ substrate. Taking biomedical TNZ alloy as contrasting materials, the electrochemical corrosion behavior and corrosion mechanism of the alloys in Ringer’s simulated body fluid were investigated by potential potentiodynamic polarization and electrochemical impedance spectroscopy (EIS) technique. The results show that the TNZ alloy exhibits good corrosion resistance due to smaller corrosion potential and smaller corrosion current density, bigger capacitive arc and wider passivation interval, and smaller corrosion pit compared with Al₂O₃/TNZ joints.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 6","pages":"1733 - 1741"},"PeriodicalIF":2.4,"publicationDate":"2025-03-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143925556","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}