Welding in the World最新文献

{"title":"Transverse varestraint weldability testing in laser powder bed fusion 316L stainless steel","authors":"Jhoan Guzman,&nbsp;Kaue C. Riffel,&nbsp;Jacque W. Berkson,&nbsp;Samuel Casto,&nbsp;Antonio J. Ramirez","doi":"10.1007/s40194-025-01933-7","DOIUrl":"10.1007/s40194-025-01933-7","url":null,"abstract":"<div><p>The use of laser powder bed fusion (LPBF) for faster and more customized manufacturing has grown significantly. However, LPBF parts often require welding to other components, raising concerns about their weldability due to differences in microstructure compared to conventionally manufactured parts. Despite its importance, research on the weldability of additive manufacturing materials remains limited. This study aims to evaluate the susceptibility of LPBF 316L stainless steel to weld solidification cracking using transverse varestraint testing and compare results with conventional 316L. Tests were conducted across strain levels from 0.5 to 7%, revealing a saturated strain of 4%, with maximum crack length (MCL), maximum crack distance (MCD), and total number of cracks (TNC) of approximately 0.36 mm and 31, respectively. Compared to existing literature, LPBF 316L produced with optimized printing parameters and low nickel equivalent content exhibited higher resistance to weld solidification cracking, reflected in lower MCL and MCD values. Cracks initiated at the solidus interface and propagated along the ferrite–austenite boundary under strain. Microstructural changes were observed after testing, transitioning from cellular austenitic solidification in LPBF to a skeletal ferrite-austenitic mode due to material remelting and slower cooling rates. These findings highlight that reduced nickel equivalent, alongside optimized printing parameters, contribute to enhanced weld solidification cracking resistance in LPBF 316L. This study advances understanding of the weldability of LPBF materials.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1045 - 1056"},"PeriodicalIF":2.4,"publicationDate":"2025-01-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-01933-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143580991","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":"Study on the improvement method of Goodman-Smith diagrams based on IIW standard and unilateral tolerance coefficient method","authors":"Jiayu Liu,&nbsp;Yuedong Wang,&nbsp;Jiaqi Zhang,&nbsp;Yuhan Tang,&nbsp;Qi Dong,&nbsp;Letian Fan","doi":"10.1007/s40194-025-01943-5","DOIUrl":"10.1007/s40194-025-01943-5","url":null,"abstract":"<div><p>The Goodman-Smith (GS) diagrams are widely used for fatigue strength assessment of bogies as a common method for welded structures. The traditional GS diagrams proposed by the UIC ORE B12/RP17 standard suffer from the problems of too large a safety factor leading to optimistic assessment results and data scarcity. Therefore, an improved method of GS diagrams for base metals and welded joints was proposed. The traditional GS diagrams were improved by combining the IIW standard and the unilateral tolerance coefficient method. The design guidelines of the traditional GS diagrams were incorporated into the improved GS diagrams to obtain the improved design guidelines. Within this framework, the improved GS diagrams were validated by applying base metal specimens with three common welded joints. The results showed that the safety factor was reduced to 0.3–0.5 times the original factor for the same survival rate and confidence level. The accuracy of the fatigue strength assessment was improved. Finally, the improved GS diagrams were used for the fatigue strength assessment of the critical base metal and weld region of the bogie frame, which provided a new reference for the fatigue strength assessment research in the field of rail transport.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"701 - 716"},"PeriodicalIF":2.4,"publicationDate":"2025-01-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396716","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":"Welding of additively manufactured aluminium alloy components: challenges and mitigation strategies","authors":"Rafael Nunes,&nbsp;Koen Faes,&nbsp;Wim Verlinde,&nbsp;Florian Probst,&nbsp;Jens De Freese,&nbsp;Julius Arnhold,&nbsp;Wim De Waele,&nbsp;Matthieu Lezaack,&nbsp;Aude Simar","doi":"10.1007/s40194-025-01923-9","DOIUrl":"10.1007/s40194-025-01923-9","url":null,"abstract":"<div><p>Additive manufacturing (AM) has contributed to significant advances in the production of aluminium alloys, particularly through powder bed fusion (PBF) and directed energy deposition (DED) processes. However, joining of conventionally and additively manufactured components remains essential. This work focuses on the weldability of AM aluminium alloys using fusion and solid-state welding processes. The study analyses the microstructural evolution and mechanical properties, revealing a relationship between AM technology and joining process. In particular, fusion welding of PBF-laser beam (LB) produced aluminium alloys presented a significant limitation due to the high porosity level, especially in the weld zone near the PBF-LB base material. This region of high porosity, known as the pore belt region, has an enormous detrimental effect on the mechanical properties of the weld. This phenomenon is not observed when the welds are carried out by solid-state welding processes, which makes this group of welding processes very suitable for this type of material. On the other hand, fusion welding of aluminium alloys produced by wire arc additive manufacturing (DED-Arc or WAAM) exhibits a good stability and repeatability, analogous to conventional aluminium alloy welding practices. Rotational friction welding of DED-Arc-produced components presented an unexpected challenge. Due to the difference in ductility compared to conventionally manufactured parts, the process window for optimal process pressure was found to be very narrow and sensitive. The findings are confirmed by metallographic examination, hardness profile measurement, tensile and bend testing.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1003 - 1021"},"PeriodicalIF":2.4,"publicationDate":"2025-01-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143580992","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":"Fatigue assessment of welded pure copper hairpins using notch stress concept","authors":"Jesse Ceruso,&nbsp;Max Mannsperger,&nbsp;Jens Mischko,&nbsp;Alfons Esderts","doi":"10.1007/s40194-024-01902-6","DOIUrl":"10.1007/s40194-024-01902-6","url":null,"abstract":"<div><p>New electrical machines for passenger cars are gaining popularity. These electrical machines which contain copper parts need to generate a magnetic field to generate the propulsion of the machine. Laser welding is a fast and an effective joining process for the copper parts. In order to determine the lifetime of the copper parts, it is necessary to assess the fatigue behavior of the laser weld seam. Current guidelines for fatigue assessment do not include copper parts or copper weld seams, hence a fatigue concept must be derived. This proceeding examines the applicability of the notch stress concept with a reference radius of 0.05 mm for copper weld seams and provides a complex and a simplified way of modeling the weld seams. The presented concept takes the geometry of the weld seams and the fracture area surfaces into account. This leads to stress results with a low scatter range and a flat slope of the S-N curve. Furthermore, the results indicate that the notch stresses are transferable.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"605 - 617"},"PeriodicalIF":2.4,"publicationDate":"2025-01-18","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-024-01902-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396561","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":"High cyclic fatigue behavior of 3D-printed titanium alloy TA15","authors":"Volodymyr Nesterenkov,&nbsp;Serhiy Akhonin,&nbsp;Illia Klochkov,&nbsp;Vladyslav Matviichuk,&nbsp;Volodymyr Berezos,&nbsp;Sviatoslav Motrunich","doi":"10.1007/s40194-025-01945-3","DOIUrl":"10.1007/s40194-025-01945-3","url":null,"abstract":"<div><p>Titanium alloy TA15, a pseudo α-alloy from the Ti–Al-Zr-Mo-V system, has garnered significant interest due to its high specific strength, excellent corrosion resistance, and superior heat resistance. This study investigates the high cyclic fatigue behavior of 3D-printed TA15, highlighting its application in aerospace, automotive, and biomedical industries. Traditional manufacturing of elements and components from TA15 involves billets and forging, ensuring high-quality metal but incurring high costs due to extensive and complex machining processes. Additive manufacturing, particularly by electron beam melting (EBM) technology, offers a promising alternative by reducing material waste and enabling rapid prototyping. This research evaluates the mechanical properties, microstructure, and fatigue performance of TA15 specimens produced via EBM. Initial findings indicate that 3D-printed TA15 exhibits strength and comparable fatigue resistance to conventionally manufactured counterparts, making it a viable option for critical applications. The study provides insights into optimizing the AM process for TA15 to enhance its performance and reliability.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"717 - 725"},"PeriodicalIF":2.4,"publicationDate":"2025-01-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396510","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 situ alloying of AlCuSi using dual-wire-directed energy deposition with plasma","authors":"S. Reinbacher,&nbsp;T. Klein,&nbsp;C. Simson,&nbsp;F. Warchomicka,&nbsp;P. Spoerk-Erdely,&nbsp;N. Enzinger","doi":"10.1007/s40194-025-01935-5","DOIUrl":"10.1007/s40194-025-01935-5","url":null,"abstract":"<div><p>The current research explores additive manufacturing of a multi-phase material using dual-wire plasma-directed energy deposition technology. With this approach, new materials can be designed and tested easily on the basis of commercially available consumables. In this work, AlSi5 and CuAl8 solid wire consumables are used to produce a specific AlCuSi alloy by controlling the welding parameters and the wire feed ratio. Initial experimentation results in an alloy with 85.7 at.% aluminum, 8.4 at.% copper, 2.7 at.% silicon, and 3.2 at.% magnesium, but with some instabilities during the process. The presence of magnesium in the chemical composition could be related to plasma interaction with the substrate during the welding process. After optimizing the process parameters, the chemical composition obtained is about 76.3 at.% aluminum, 19.9 at.% copper, and 3.8 at.% silicon. Using microstructural analysis via light and scanning electron microscopy, defects such as pores and inadequately melted Cu wire material are observed in all materials produced. Although the optimization of the melting process improved the microstructure, it also increased the copper content, which in turn exerts a significant influence on the mechanical properties. Mechanical testing indicates significant embrittlement. The results underscore that the microstructure is heavily influenced by the chemical composition. Microstructural changes caused by the higher copper content, i.e., in particular the increase of the volume fraction of brittle intermetallic phases such as θ-Al₂Cu, result in severe embrittlement of the obtained materials, denoted by higher hardness and reduced toughness. We conclude that the use of dual-wire plasma additive manufacturing can develop new materials by in situ alloying.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"849 - 859"},"PeriodicalIF":2.4,"publicationDate":"2025-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-025-01935-5.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396509","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":"Detection of hot water boiler tubes inner surface damages at early stage of their development using the metal magnetic memory method","authors":"Anatoly Dubov,&nbsp;Alexander Dubov,&nbsp;Sergey Kolokolnikov,&nbsp;Artem Marchenkov","doi":"10.1007/s40194-025-01934-6","DOIUrl":"10.1007/s40194-025-01934-6","url":null,"abstract":"<div><p>Operational reliability of boilers and heat exchangers strongly depends on reliability of heating surface tubes. A wide range of non-destructive testing (NDT) technologies applied for their diagnostics includes various methods of eddy current testing, magnetic stray fields, an ultrasonic immersion echo method, laser optics, and visual inspection. However, all the above methods have limitations in their application. Moreover, conventional NDT methods are aimed at detecting only the existent defects. One of the solutions to prevent unexpected damages of heating surface tubes is the application of stress–strain state (SSS) control methods. This approach allows detecting the stress concentration zones (SCZs) as the main sources of the future defects initiation. Therefore, it becomes possible to identify defects at an early stage of their development, and monitor their propagation. The metal magnetic memory (MMM) method is a passive technique of magnetic testing. It is based on the self-magnetic stray field analysis that allows assessing the SSS of tested objects. The MMM method is used as a screening tool for diagnosis of impending failure of critical industrial equipment. The article discusses the MMM method application for the inspection of the inner surface of the boiler heat exchanger steel tubes. The examples of the SCZs detection and the identification of defects in these zones at an early stage of their development are presented. The influence of the revealed SCZs on the strength characteristics of the tube metal is shown. The relationship between the material strength characteristics and the magnetic characteristics of MMM testing is presented calculating the magnetic strain index <i>m</i>.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"727 - 738"},"PeriodicalIF":2.4,"publicationDate":"2025-01-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396508","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":"High-power ultrasonic spot welding of copper to type 304L austenitic stainless steel","authors":"Mohamed Wahba,&nbsp;Sami M. Ibn Shamsah,&nbsp;Mohamed A. H. Gepreel,&nbsp;Macoto Takahashi","doi":"10.1007/s40194-024-01905-3","DOIUrl":"10.1007/s40194-024-01905-3","url":null,"abstract":"<div><p>The demand for a robust welding technique capable of joining copper and steel is driven by their extensive application across various industrial sectors. Addressing the limitations of current welding methods, this study explores the effectiveness of ultrasonic welding in joining commercially pure copper to type 304L stainless steel. The effects of different welding parameters on the characteristics of the welded joints were investigated. The results demonstrate the successful welding of the two metals without inserting an interlayer despite the metallurgical immiscibility of copper and iron. The interfacial bond density and the joint strength were found to increase with the applied welding energy. A joint strength of approximately 80% of the base copper strength was obtained. Transmission electron microscopy (TEM) analysis unveiled a well-bonded interface with excellent continuity between the two metals. A diffusion layer containing nano-sized chromium-rich oxide or intermetallic compound particles was observed. It was noticed that copper penetrated the partially disrupted chromium-rich oxide layer reaching and developing intimate contact with the newly uncoated stainless steel surface. A synergy of mechanical interlocking and solid-state metallurgical adhesion was revealed for the bonding mechanism in addition to potential metallurgical interactions at the interface.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 2","pages":"555 - 569"},"PeriodicalIF":2.4,"publicationDate":"2025-01-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-024-01905-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143108417","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":"Investigating the effect of varying powder size range on particulate matter emission and mechanical properties of in situ micropowder alloyed WAAM depositions","authors":"Adarsh Prakash,&nbsp;Rubal Dhiman,&nbsp;Anirudha Ambekar,&nbsp;Thaseem Thajudeen,&nbsp;Sachin Dnyandeo Kore","doi":"10.1007/s40194-024-01922-2","DOIUrl":"10.1007/s40194-024-01922-2","url":null,"abstract":"<div><p>Wire Arc Additive Manufacturing (WAAM) fabricates 3D products by laying molten filler wire in layers, resulting in final products with properties similar to the parent filler wire. In situ micro powder alloying during WAAM can modify the deposited material without changing the parent filler material to enhance its mechanical properties. This study investigates the effects of adding titanium (Ti) and copper (Cu) micro powders in different size ranges (&lt; 25 µm, 25–45 µm, and 45–95 µm), within the layers of carbon steel in multilayered vertical walls during WAAM. The analysis of the variations in the mechanical and metallurgical properties of WAAM deposited samples is also done along with the dynamics of fine and ultrafine particle (UFP) emissions resulting from WAAM depositions, with and without the incorporation of CuTi powder. Real-time data acquisition of particulate matter (PM) concentration was carried out with a combination of low-cost particulate matter sensors (LCS) and scanning mobility particle sizer (SMPS). The incorporation of CuTi powder in various sizes has been observed to improve the mechanical properties, with the most significant enhancement noted in samples containing CuTi powder with sizes ranging from 25 to 45 µm. This improvement is likely attributable to the superior adhesion and uniform distribution of these particles across the surface compared with samples containing CuTi powder of finer size ranges. Variations in PM and UFP levels across different sizes of CuTi powder revealed that smaller-sized CuTi particles (less than 25 µm or 25–45 µm) demonstrate superior combustion compared with larger particles (45–95 µm). Consequently, larger particles contribute to higher PM and UFP emissions. The importance of micro powder size on mechanical properties enhancement is studied in detail along with the emission characteristics of CuTi micropowder added WAAM depositions, to understand the potential for identifying an optimized size range of micropowders.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 4","pages":"1171 - 1190"},"PeriodicalIF":2.4,"publicationDate":"2025-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143581139","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 influence of weld start reentrant angle on fatigue life determined through analysis and physical testing","authors":"D. Bradley Cook,&nbsp;Christy Lee,&nbsp;Donald Stickel","doi":"10.1007/s40194-024-01906-2","DOIUrl":"10.1007/s40194-024-01906-2","url":null,"abstract":"<div><p>The influence of acute toe reentrant angle on fatigue life at a robotic weld start location was investigated both analytically using linear elastic fracture mechanics (LEFM) and through physical testing. 2D LEFM results show no significant change in stress intensity factor (SIF) within a toe reentrant angle range of 60 degrees (acute) to 120 degrees (obtuse). 3D LEFM was used to compare crack growth rates for idealized 60- and 90-degree weld start geometry. Crack propagation was identical for these two cases. Physical fatigue test specimens were created with two distinct toe reentrant angle groups averaging 68 and 103 degrees at the weld start locations. Fatigue failure cycles at three stress ranges for the two groups produced similar stress-life trends. The study concludes that local weld start acute toe reentrant angle change between 60 and 90 degrees does not significantly influence the joint fatigue life under axial loading.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"69 3","pages":"633 - 642"},"PeriodicalIF":2.4,"publicationDate":"2025-01-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143396462","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}