Welding in the World最新文献

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Numerical and experimental analysis of the vibration propagation of ultrasonically welded cable-arrester connections 超声焊接电缆-避雷器接头振动传播的数值与实验分析
IF 3.1 4区 材料科学
Welding in the World Pub Date : 2026-03-05 DOI: 10.1007/s40194-026-02405-2
Kai Ehlich, Moritz Kranz, Michael Hasieber, Jean Pierre Bergmann
{"title":"Numerical and experimental analysis of the vibration propagation of ultrasonically welded cable-arrester connections","authors":"Kai Ehlich,&nbsp;Moritz Kranz,&nbsp;Michael Hasieber,&nbsp;Jean Pierre Bergmann","doi":"10.1007/s40194-026-02405-2","DOIUrl":"10.1007/s40194-026-02405-2","url":null,"abstract":"<div><p>Ultrasonic metal welding (USMW) is widely applied in the transportation industry for the production of lightweight electrical connections, particularly in cable arrester joints for electric vehicles. While the process offers low joining temperatures and short cycle times, ultrasonic vibrations can interfere with previously welded joints, potentially causing degradation. Therefore, a mechanistic understanding of vibration propagation during USMW and its impact on existing joints is required to ensure process reliability. This study investigates vibration propagation and joint degradation in stranded wire to arrester connections welded at both ends using linear USMW. EN AW-1370 aluminum stranded wires with a cross section of 50 mm<sup>2</sup> and varying lengths between 150 and 1000 mm were welded to CW004A copper terminals. Experimental investigations included laser vibrometry, high-speed videography, and tensile shear testing. In parallel, a scaled finite element model was developed in ANSYS Workbench and validated against experimental data. Mechanical testing revealed a strong dependence of joint integrity on cable length, with robust joints at 300 mm, non-weldable behavior at 225 mm, and isolated failures at 150 mm and 375 mm, while longer cables exhibited no indications of joint degradation. Laser vibrometry indicated decreasing vibration amplitudes with increasing length due to damping, whereas critical lengths were characterized by pronounced amplitude and phase shifts associated with weld degradation. Finite element simulations reproduced these effects and identified elevated weld-zone stresses at critical lengths of approximately 130 MPa. Unsynchronized vibration transmission, expressed by relative phase shifts, was identified as the primary cause of joint failure.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 7","pages":"3107 - 3122"},"PeriodicalIF":3.1,"publicationDate":"2026-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-026-02405-2.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148261792","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}
引用次数: 0
A novel method for extracting weld seam by fusing semantic segmentation and point cloud features 一种融合语义分割和点云特征的焊缝提取新方法
IF 3.1 4区 材料科学
Welding in the World Pub Date : 2026-03-05 DOI: 10.1007/s40194-026-02415-0
Haicheng Su, Qinghao Liao, Zheng Qing, Wei Li, Jianchun Liu
{"title":"A novel method for extracting weld seam by fusing semantic segmentation and point cloud features","authors":"Haicheng Su,&nbsp;Qinghao Liao,&nbsp;Zheng Qing,&nbsp;Wei Li,&nbsp;Jianchun Liu","doi":"10.1007/s40194-026-02415-0","DOIUrl":"10.1007/s40194-026-02415-0","url":null,"abstract":"<div><p>Manual weld inspection suffers from low efficiency and difficulties in quantification, while 3D point cloud-based detection often encounters data redundancy and high computational costs. To address these issues, this paper proposes an automated weld seam extraction method that synergistically integrates 2D semantic segmentation with 3D point cloud feature processing. The process begins by employing an efficient, lightweight YOLOv11-Seg model to perform semantic segmentation on RGB images of welded workpieces, thereby locating the weld region of interest (ROI). The initial segmentation mask is then compensated and optimized using morphological operations to ensure complete coverage of the weld area. Subsequently, a single-mask dual-region phase-constraint strategy is introduced to restrict the point cloud computation strictly to the weld seam ROI, effectively suppressing background point cloud generation at the source and significantly improving reconstruction efficiency. Finally, an enhanced RANSAC algorithm, termed Normal-Guided and Dual-Threshold RANSAC (NGDT-RANSAC), which incorporates normal guidance and a dual-threshold inlier determination mechanism, is developed to achieve precise separation between the base-metal planes and the weld point cloud. Experimental results demonstrate that the proposed method achieves efficient and accurate extraction and segmentation of weld point clouds, with precision and Intersection over Union (IoU) reaching 98.5% and 97.7%, respectively, and an average edge segmentation error of 0.2 mm. The entire process, from acquisition to segmentation of point clouds comprising tens of thousands of points, is completed within 4 s, confirming its high efficiency and reliability for practical engineering applications.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 11","pages":"5599 - 5617"},"PeriodicalIF":3.1,"publicationDate":"2026-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149189338","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}
引用次数: 0
Influence of build-up height on residual stresses in additive repair and modification using DED-Arc with high-strength filler metals 堆焊高度对高强度填充金属d-电弧增材修复和改性过程中残余应力的影响
IF 2.5 4区 材料科学
Welding in the World Pub Date : 2026-03-04 DOI: 10.1007/s40194-026-02417-y
R. Scharf-Wildenhain, L. Engelking, A. Haelsig, D. Schroepfer, T. Kannengiesser, J. Hensel
{"title":"Influence of build-up height on residual stresses in additive repair and modification using DED-Arc with high-strength filler metals","authors":"R. Scharf-Wildenhain,&nbsp;L. Engelking,&nbsp;A. Haelsig,&nbsp;D. Schroepfer,&nbsp;T. Kannengiesser,&nbsp;J. Hensel","doi":"10.1007/s40194-026-02417-y","DOIUrl":"10.1007/s40194-026-02417-y","url":null,"abstract":"<div><p>Directed energy deposition (DED)-Arc is suitable for the hybrid additive manufacturing, modification and repair of large metal components with high deposition rates. Residual stresses and distortion are of central importance when characterizing the manufactured components and the sensitive transition area between additive manufactured (AM) component and semi-finished product. Residual stresses caused by the thermal cycles during the manufacturing process can impair the mechanical properties of the manufactured parts and can lead to component failure, especially for high-strength steels. Therefore, understanding and controlling residual stresses, when combining different base and feedstock materials, is critical to improve the quality and efficiency of the hybrid DED-Arc process. This article deals with the influence of the build-up height on the residual stress distribution of additively manufactured components with a selected base and feedstock material from commercial high-strength steels. Using a robot-assisted DED-system and a controlled short arc, AM welding experiments were carried out with close to the application parameters at working temperature (200 °C) and heat input (650 kJ/m). Five hybrid AM specimens (AM wall on upright structural steel plate) were produced using a one bead per layer strategy and selected AM-wall heights between 15 and 300 mm. The influence of the AM build height on the longitudinal residual stress in the whole hybrid AM specimen (in welding direction) was analyzed and discussed. All experiments exhibit comparable stress distributions in the area of the substrate plate up to the heat-affected zone (HAZ) and the transition zone, regardless of the building height. The height significantly influences the residual stress distribution of the deposited AM-component. Tensile residual stresses with a maximum range between 300and 400 MPa were always found in the last approx. 18 component layers (upper 40 mm). This is due to restraint of the shrinking of the top layers by the layers below. The lower layers show homogeneous residual stress distributions characterized by low compressive stresses due to the process-related tempering during the deposition of each layer on top of each other. As a result, the significant difference between the various AM build-up heights of the hybrid AM specimens is the extent (or height) of this tempered zone with low compressive stresses. These correlations contribute to the understanding of residual stress development with increasing structure height or ratio of component heights of substrate semi-finished product and AM component in hybrid additive manufacturing.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 5","pages":"2025 - 2036"},"PeriodicalIF":2.5,"publicationDate":"2026-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-026-02417-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147727420","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}
引用次数: 0
PIHT heat input regulation for synergistic control of manufacturing quality and mechanical properties in DED-Arc 304 stainless steel 用于协同控制d - arc 304不锈钢制造质量和机械性能的PIHT热输入调节
IF 3.1 4区 材料科学
Welding in the World Pub Date : 2026-03-04 DOI: 10.1007/s40194-026-02392-4
Haihua Liu, Jia Li, Zeming Li, Yu Fu
{"title":"PIHT heat input regulation for synergistic control of manufacturing quality and mechanical properties in DED-Arc 304 stainless steel","authors":"Haihua Liu,&nbsp;Jia Li,&nbsp;Zeming Li,&nbsp;Yu Fu","doi":"10.1007/s40194-026-02392-4","DOIUrl":"10.1007/s40194-026-02392-4","url":null,"abstract":"<div><p>Directed Energy Deposition-Arc (DED-Arc) is promising for large-scale metal component manufacturing due to its high efficiency and low cost, but residual stress and deformation from layer-by-layer deposition limit its application. To address the “synergistic control of forming quality and performance,” this study introduces Plasma In-situ Heat Treatment (PIHT) as a synchronous thermal regulation strategy, aiming to explore how PIHT heat input affects the forming quality of DED-Arc-fabricated 304 stainless steel components. A 3D transient thermo-mechanical coupled finite element model (with double ellipsoid plasma heat source) was integrated with experiments (VIC-3D full-field strain measurement and infrared thermal imager) to systematically analyze the effects of PIHT heat input (0.384–0.768 kJ/mm) on temperature field, stress-strain field, mechanical properties, and microstructure. Results show PIHT effectively regulates the welding thermal cycle and improves temperature field uniformity, while excessive heat input causes heat accumulation. The heat input exhibits a non-linear relationship with substrate deformation and residual stress, with an optimal window identified. At 0.672 kJ/mm, longitudinal and transverse equivalent stresses are reduced by  ~57%, residual tensile stresses by ~66% and 52% respectively, and substrate deformation reaches the minimum (1.17 mm). This optimal parameter achieves the best comprehensive mechanical properties (tensile strength = 577/623 MPa, elongation = 16%/17%, microhardness = 225 HV) with uniform distribution. Microstructural analysis indicates PIHT balances grain refinement and second-phase precipitation, avoiding excessive fineness or coarseness defects.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 11","pages":"5539 - 5560"},"PeriodicalIF":3.1,"publicationDate":"2026-03-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149189293","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}
引用次数: 0
Enhancing microstructure and mechanical properties of Inconel 625 by a low-cost static magnetic field-assisted WAAM process 采用低成本的静态磁场辅助WAAM工艺提高Inconel 625的显微组织和力学性能
IF 3.1 4区 材料科学
Welding in the World Pub Date : 2026-03-03 DOI: 10.1007/s40194-026-02408-z
Shang-Pang Yu, Wei-Peng Liu, Chia-Yuan Hsieh, Yu-Wei Lee
{"title":"Enhancing microstructure and mechanical properties of Inconel 625 by a low-cost static magnetic field-assisted WAAM process","authors":"Shang-Pang Yu,&nbsp;Wei-Peng Liu,&nbsp;Chia-Yuan Hsieh,&nbsp;Yu-Wei Lee","doi":"10.1007/s40194-026-02408-z","DOIUrl":"10.1007/s40194-026-02408-z","url":null,"abstract":"<div><p>Wire arc additive manufacturing of nickel-based superalloys often suffers from limited deposition stability, microstructural inhomogeneity, and mechanical anisotropy, which restrict its broader industrial application. This study aims to evaluate the feasibility of using a static magnetic field as a low-cost, passive, and energy-free process control strategy for WAAM-fabricated Inconel 625. A GMAW-based WAAM system was employed under different transverse static magnetic field conditions, and the resulting build geometry, microstructural characteristics, and mechanical properties were systematically investigated. The results show that an appropriate magnetic field intensity increased the build height by 15.3% while improving surface morphology and deposition stability. Microstructural observations revealed noticeable changes in solidification morphology and improved microstructural uniformity. Elemental analysis indicated a significant reduction in Nb and Mo segregation, while XRD peak broadening suggested refined microstructural features and partial residual stress release. The average microhardness increased by approximately 6–7% with a more uniform distribution. The ultimate tensile strength increased from 729/660 MPa (horizontal/vertical) to 775/692 MPa, corresponding to improvements of 6.3% and 4.8%, respectively, accompanied by more uniformly distributed ductile fracture features. Overall, the results demonstrate that static magnetic field assistance can effectively enhance molten pool convection, improve microstructural homogeneity, and enhance mechanical performance in WAAM-fabricated Inconel 625, highlighting its potential as a simple and industrially applicable process control approach.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 11","pages":"5495 - 5509"},"PeriodicalIF":3.1,"publicationDate":"2026-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-026-02408-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149189346","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}
引用次数: 0
Resistance welding for future hydrogen economy—the comeback of an old welding technology for modern applications 未来氢经济的电阻焊——一种古老的焊接技术在现代应用中的回归
IF 3.1 4区 材料科学
Welding in the World Pub Date : 2026-03-03 DOI: 10.1007/s40194-026-02402-5
Maike Epperlein, Martin Aretz, Alexander Schiebahn, Uwe Reisgen
{"title":"Resistance welding for future hydrogen economy—the comeback of an old welding technology for modern applications","authors":"Maike Epperlein,&nbsp;Martin Aretz,&nbsp;Alexander Schiebahn,&nbsp;Uwe Reisgen","doi":"10.1007/s40194-026-02402-5","DOIUrl":"10.1007/s40194-026-02402-5","url":null,"abstract":"<div><p>Upscaling hydrogen production through water electrolysis with proton exchange membranes (PEM) has established high interest in several industrial fields to achieve the ambitious goals given by legislative bodies regarding production volumes and cost reductions. One approach is the substitution of sintered bodies with joined multi-layered expanded metal mesh (EMM) composites that are used as porous transport layers in PEM electrolysis. For joining the multi-layered structures, capacitor discharge welding is a favored welding technology, which offers the possibility for automation, while being a highly economic and robust process. But since EMM exhibits anisotropic properties as well as a wide variety of mesh geometries, the design of such multi-layered composites leads to various possibilities for modifying the properties of the composites in terms of flow characteristics and cell efficiency. Simultaneously, these variations also influence the joining process itself. In this paper, different EMM geometries are joined in 90°- and 180°-layer-to-layer orientation in a resistance projection welding process with capacitor discharge welding. While compression tests reveal improved damping characteristics for 90°-orientation, the CFD simulation hints at more pronounced turbulences in fluid flow which are assumed to favor gas bubble accumulation and a cell efficiency decrease. Contrary, for 180°-orientation less flow turbulences and a smaller pressure drop across the cell are revealed.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 7","pages":"3089 - 3105"},"PeriodicalIF":3.1,"publicationDate":"2026-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1007/s40194-026-02402-5.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148261757","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}
引用次数: 0
Controlling microstructure and mechanical properties of directed energy deposition-arc fabricated 18Ni-350 maraging steel through inter-layer temperature adjustment 通过层间温度调节控制定向能沉积电弧制备18Ni-350马氏体时效钢的组织和力学性能
IF 3.1 4区 材料科学
Welding in the World Pub Date : 2026-03-03 DOI: 10.1007/s40194-026-02412-3
Hong Li, Qizhu Yan, Erika Hodúlová, Longfei Song, Xiaoyong Zhang, Zhuoxin Li, Yipeng Wang
{"title":"Controlling microstructure and mechanical properties of directed energy deposition-arc fabricated 18Ni-350 maraging steel through inter-layer temperature adjustment","authors":"Hong Li,&nbsp;Qizhu Yan,&nbsp;Erika Hodúlová,&nbsp;Longfei Song,&nbsp;Xiaoyong Zhang,&nbsp;Zhuoxin Li,&nbsp;Yipeng Wang","doi":"10.1007/s40194-026-02412-3","DOIUrl":"10.1007/s40194-026-02412-3","url":null,"abstract":"<div><p>Directed energy deposition-arc (DED-arc) enables the fabrication of large maraging steel components, yet its high heat input often results in suboptimal mechanical properties. This study investigates the effect of inter-layer temperature—150 °C and 200 °C—on the microstructure and mechanical properties of DED-arc-fabricated 18Ni350 maraging steel. Thin walls were deposited under the two temperature regimes, followed by comprehensive characterization of thermal history, microstructure, and mechanical properties. Results indicate that the lower inter-layer temperature of 150 °C promotes faster cooling, leading to a finer grain structure, higher martensite content, and reduced retained austenite compared to 200 °C. These microstructural refinements contribute directly to enhanced mechanical properties, including higher average microhardness (369 HV vs. 341 HV) and superior tensile performance. The 150 °C condition achieves a vertical tensile strength of 1267 MPa with 14.2% elongation and a horizontal strength of 1200 MPa with 14.9% elongation, outperforming the 200 °C condition (1229 MPa, 7.9% vertically; 1076 MPa, 11.9% horizontally). The work demonstrates that controlling inter-layer temperature near the martensite start temperature effectively optimizes microstructure and achieves an excellent strength–ductility balance in DED-arc produced maraging steel.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 11","pages":"5523 - 5538"},"PeriodicalIF":3.1,"publicationDate":"2026-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149189347","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}
引用次数: 0
Toward predictive additive manufacturing: ML-based hardness prediction for Ti–6A1–4 V in laser powder bed fusion 面向预测增材制造:基于ml的激光粉末床熔合Ti-6A1-4 V硬度预测
IF 3.1 4区 材料科学
Welding in the World Pub Date : 2026-03-03 DOI: 10.1007/s40194-026-02409-y
Amir Reza Ansari Dezfoli, Yi-Jen Huang, Sanaz Hadidchi
{"title":"Toward predictive additive manufacturing: ML-based hardness prediction for Ti–6A1–4 V in laser powder bed fusion","authors":"Amir Reza Ansari Dezfoli,&nbsp;Yi-Jen Huang,&nbsp;Sanaz Hadidchi","doi":"10.1007/s40194-026-02409-y","DOIUrl":"10.1007/s40194-026-02409-y","url":null,"abstract":"<div><p>Laser powder bed fusion (LPBF) of Ti–6Al–4 V frequently yields high hardness, but the result is sensitive to coupled process settings. This work investigates whether hardness can be predicted directly from the process parameters to support data-driven process planning. A literature-derived dataset of 136 cases was compiled with laser power, scan speed, layer thickness, hatch distance, and spot size as inputs and Vickers hardness as the output. Five regression models were compared: gradient boosting, random forest, support vector regression (SVR), a feed-forward neural network, and L1-regularized linear regression. The models were assessed using cross-validation and a data split of 85%/15% for training and testing. Ensemble tree methods delivered the most accurate predictions, with gradient boosting achieving the highest explanatory power <span>(left({R}^{2}=0.705right))</span> with low error (RMSE = 22.015 HV; MAE = 13.873 HV; MAPE = 3.834%), followed by random forest (<span>({R}^{2}=0.595)</span>). The neural network, linear model, and SVR performed substantially worse due to limited capacity or misspecification for the interaction-rich small-sample setting. Distributional analysis showed that the dataset clusters around common LPBF presets (e.g., 30-μm layers, ∼0.1-mm hatch), while hardness was concentrated near ∼380 HV. Overall, the results indicate that ensemble models capture the dominant nonlinearities linking LPBF parameters to hardness and can serve as practical surrogates for predictive design and preliminary optimization of Ti–6Al–4 V builds.\u0000</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 11","pages":"5511 - 5521"},"PeriodicalIF":3.1,"publicationDate":"2026-03-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149189345","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}
引用次数: 0
Inverse determination of welding current and travel speed for GMAW butt-welded pipe joint GMAW对焊管接头焊接电流和速度的反测定
IF 3.1 4区 材料科学
Welding in the World Pub Date : 2026-02-28 DOI: 10.1007/s40194-026-02396-0
Van-The Than, Thi-Thao Ngo, Jin H. Huang, Chi-Chang Wang, Khac-Khanh Bui, Thanh-Phu Nguyen, Danh-Dao Nguyen
{"title":"Inverse determination of welding current and travel speed for GMAW butt-welded pipe joint","authors":"Van-The Than,&nbsp;Thi-Thao Ngo,&nbsp;Jin H. Huang,&nbsp;Chi-Chang Wang,&nbsp;Khac-Khanh Bui,&nbsp;Thanh-Phu Nguyen,&nbsp;Danh-Dao Nguyen","doi":"10.1007/s40194-026-02396-0","DOIUrl":"10.1007/s40194-026-02396-0","url":null,"abstract":"<div><p>Accurate identification of welding parameters is essential for ensuring weld quality and reducing trial and error procedures in GMAW pipe welding. This study presents an inverse method for directly estimating the welding current and welding travel speed. A transient finite-element thermal model was developed to generate direct temperature responses, and a conjugate-gradient algorithm was employed to retrieve the unknown parameters from temperature measurements on the pipe surface. Comprehensive sensitivity analyses were carried out to evaluate the influence of sensor number, sensor placement, measurement distance, and measurement error. The results demonstrate that the proposed method can accurately estimate both welding current and travel speed based on only two optimally positioned sensors even if measurement error is involved. The results also reveal that the measurement points located at weld start provided stronger temperature information and superior convergence behavior compared with the points near the weld end. Additional verification cases further confirmed the robustness and general applicability of the approach. The proposed method can be applied for various kinds of welding as well as welding materials.\u0000</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 11","pages":"5443 - 5470"},"PeriodicalIF":3.1,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149189649","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}
引用次数: 0
Reliability assessment of ultrasonic welded and crimped connections for high-current copper wire applications 大电流铜线用超声波焊接和卷曲连接的可靠性评估
IF 3.1 4区 材料科学
Welding in the World Pub Date : 2026-02-28 DOI: 10.1007/s40194-026-02398-y
Hafiz Abdul Saboor, Basit Ali Khan, Yingzhong Tian
{"title":"Reliability assessment of ultrasonic welded and crimped connections for high-current copper wire applications","authors":"Hafiz Abdul Saboor,&nbsp;Basit Ali Khan,&nbsp;Yingzhong Tian","doi":"10.1007/s40194-026-02398-y","DOIUrl":"10.1007/s40194-026-02398-y","url":null,"abstract":"<div><p>The reliability of electrical connections is critical in high-current applications, where joint performance directly influences efficiency, safety, and service life. In this study, a comparative investigation of ultrasonic welding (USW) and crimping was conducted for joining 16 mm<sup>2</sup> copper conductors to silver-coated copper substrates. Mechanical testing, microstructural and compositional analysis (SEM/EDS and XRD), electrical resistance measurements, infrared thermography, and salt spray corrosion evaluations were employed to assess the performance and degradation behavior of both joining methods. Tensile results showed that crimped joints exhibited higher initial strength, whereas USW joints maintained superior interfacial integrity under corrosive conditions. Microhardness measurements indicated lower hardness at the USW interface (65–75 HV) compared to crimped joints (82–88 HV), reflecting differences in bonding mechanisms. SEM/EDS and XRD analyses confirmed metallurgical bonding and enhanced oxidation resistance in USW joints, while crimped joints relied primarily on mechanical interlocking and showed greater susceptibility to interfacial degradation. Electrical measurements revealed that crimped joints generally exhibited lower resistance but higher variability, whereas USW joints demonstrated more stable electrical behavior. Infrared thermography further indicated more uniform and stable thermal responses for USW joints under current loading. Unlike previous comparative studies that mainly emphasize initial mechanical or electrical performance, this work focuses on reliability and degradation behavior by correlating interfacial bonding mechanisms with mechanical, electrical, and thermal stability. The results provide new insight into the long-term performance of high-current copper connections and offer practical guidance for selecting joining technologies in demanding industrial applications.</p></div>","PeriodicalId":809,"journal":{"name":"Welding in the World","volume":"70 7","pages":"3057 - 3073"},"PeriodicalIF":3.1,"publicationDate":"2026-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148261830","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}
引用次数: 0
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