Dissimilar Components Research Articles

Heterogeneous interfaces of aluminum bronze/Inconel 718 dissimilar alloys under different wire arc directed energy deposition sequences

Abstract The layer-by-layer deposition strategy of additive manufacturing makes it ideal to fabricate dissimilar alloy components with varying functionality, which has promising application potential in a large number of industrial areas. In this study, two components composed of ERCuAl-A2 aluminum bronze (CuAl9) and Inconel 718 nickel-based superalloy were fabricated with different deposition orders by wire-arc directed energy deposition. Subject to changes in heat input and thermophysical properties of the substrate, the transition region of the deposited Cu–Ni component with the bottom half of CuAl9 and the top half of Inconel 718 is narrow and serrated. This region features a laminated intermetallic compound layer due to the convection and rapid cooling in the molten pool. In contrast, the Ni–Cu component deposited in the opposite order exhibits a 2 mm gradient transition zone. Within this region, a large number of diverse precipitates were found as well as regional variations in grain size due to the multi-layer partial remelting. Both two components show strong bonds and their tensile specimens tested along the vertical direction always fracture at the softer CuAl9 side. Excellent tensile properties along the horizontal direction were obtained for Cu–Ni (Ultimate tensile strength: 573 MPa, yield stress: 302 MPa, elongation: 22%), while those of Ni–Cu are much lower due to the existence of the solidification cracks in the transition zone. The results from this study provide a reference for the additive manufacturing of Cu/Ni dissimilar alloy components, as well as their microstructure and mechanical properties control.

Study on Mitigation of Interfacial Intermetallic Compounds by Applying Alternating Magnetic Field in Laser-Directed Energy Deposition of Ti6Al4V/AA2024 Dissimilar Materials

Brittle intermetallic compounds (IMCs) at the interface of dissimilar materials can seriously affect the mechanical properties of the dissimilar components. Introducing external assisted fields in the fabrication of dissimilar components is a potential solution to this problem. In this study, an alternating magnetic field (AMF) was introduced for the first time in the additive manufacturing of Ti6Al4V/AA2024 dissimilar alloy components by laser-directed energy deposition (L-DED). The effect of the AMF on the interfacial IMCs’ distribution was studied. The results indicate that the contents of the IMCs were different for different magnetic flux densities and frequencies, and the lowest content was obtained with a magnetic flux density of 10 mT at a frequency of 40 Hz. When an appropriate AMF was applied, the IMC layer was no longer continuous at the interface, and the thickness was notably decreased. In addition, the influence of the AMF on the temperature distribution and fluid flow in the melt pool was analyzed through numerical simulation. The simulation results indicate that the effect of the AMF on the temperature of the melt pool was not significant, but it changed the flow pattern inside the melt pool. The two vortices inside the cross-section that formed when the AMF was applied caused different orientations of club-shaped IMCs inside the deposition layer. A sudden change in the streamline direction at the bottom of the longitudinal cross-section of the melt pool can affect the formation of the IMC layer at the interface of dissimilar materials, resulting in inconsistent thickness and even gaps. This work provides a useful guidance for regulating IMCs at dissimilar material interfaces.

Friction Stir-Based Techniques: An Overview

AbstractFriction stir-based techniques (FSTs), originating from friction stir welding (FSW), represent a solid-state processing method catering to the demands of various industrial sectors for lightweight components with exceptional properties. These techniques have gained much more attraction by providing an opportunity to tailor the microstructure and enhance the performance and quality of produced welds and surfaces. While significant attention has historically been directed towards the FSW process, this review delves into the working principles of FSTs, exploring their influence on mechanical properties and microstructural characteristics of various materials. Additionally, emphasis is placed on elucidating the advancement of hybrid FSW processes for both similar and dissimilar metal components, aimed at enhancing welding quality through meticulous control of grain textures, structures, precipitation, and phase transformations. Finally, the review identifies current knowledge gaps and suggests future research directions. This review paper synthesises academic literature sourced from the Web of Science (WoS) and Scopus databases, supplemented by additional sources such as books from the last 15 years.

Qualitative analysis of Fasciola gigantica excretory and secretory products coimmunoprecipitated with buffalo secondary infection sera shows dissimilar components from primary infection sera

Buffaloes cannot mount a robust adaptive immune response to secondary infection by Fasciola gigantica. Even if excretory and secretory products (ESPs) exhibit potent immunoregulatory effects during primary infection, research on ESPs in secondary infection is lacking, even though the ESP components that are excreted/secreted during secondary infection are unknown. Therefore, qualitative analysis of ESP during secondary infection was performed and compared with that of primary infection to deepen the recognition of secondary infection and facilitate immunoregulatory molecules screening. Buffaloes were divided into three groups: A (n = 3, noninfected), B (n = 3, primary infection) and C (n = 3, secondary infection). Buffaloes in the primary (0 weeks post infection; wpi) and secondary (-4 and 0 wpi) infection groups were infected with 250 metacercariae by oral administration. Then, sera were collected from groups at different wpi, and interacting proteins were precipitated by coimmunoprecipitation (Co-IP), qualitatively analyzed by liquid chromatography-tandem mass spectrometry (LC-MS/MS), and annotated by Gene Ontology (GO) and Kyoto Encyclopedia of Genes and Genomes (KEGG) analyses to infer their potential functions. In group C, 324 proteins were identified, of which 76 proteins were consistently identified across 7 time points (1, 3, 6, 8, 10, 13, and 16 wpi). Compared with 87 proteins consistently identified in group B, 22 proteins were identified in group C. Meanwhile, 34 proteins were only identified in group C compared to 200 proteins identified in group B. Protein pathway analysis indicated that these proteins were mainly involved in the cellular processes and metabolism of F. gigantica. Among them, 14–3–3θ was consistently identified in group C and may be involved in various cellular processes and innate immune signalling pathways. Members of the HSP family were identified in both groups B and C and may function in both primary and secondary infection processes. The proteins discovered in the present study will help to deepen the understanding of the molecular interactions between F. gigantica and buffalo during secondary infection and facilitate the identification of new potential immunoregulatory molecules.

Phase behavior of the carbon dioxide/toluene/poly(ethylene glycol) ternary system

The phase behavior of a carbon dioxide (CO2)/toluene (Tol)/poly(ethylene glycol) (PEG) ternary system was investigated in this study to consider the effect of the polymer species on the phase diagram. Measurements were performed using a synthetic method combined with laser displacement and turbidity measurements. Bubble points (vapor–liquid phase separation) were determined from changes in the piston displacement and cloud points (liquid–liquid (LL) phase separation) were determined from changes in the turbidity. The phase boundaries of the CO2 mass fractions ranging from 0.113 to 0.496 were measured by varying the Tol/PEG mass ratio. The homogeneous phase area decreased when the mass ratio of PEG to Tol increased and/or the temperature decreased. These changes in the LL phase-separation behavior were explained by referring to the free volume fraction and solubility parameter estimated using the Sanchez–Lacombe equation of state. The free volume integral fraction could explain the phase diagram, but not the solubility parameter; the effect of polymer species on the Px phase diagram of the ternary system was explained by considering specific interactions between dissimilar components. These results could promote a comprehensive understanding of the phase diagram of CO2/organic solvent/polymer systems and aid the prediction of phase behavior.

Case study of a cluster of simple and complex monogenetic volcanoes in the north‐east part of the Michoacan–Guanajuato Volcanic Field, Central Mexico: Nomenclature implications

With the advent of new terminologies to categorize and characterize the simple and complex monogenetic volcanoes, also came the semantic issues, which caused a predicament for the usage of terms like simple, complex, polycyclic, polymagmatic, complex monogenetic volcanoes with polygenetic inheritance. To analyse and validate this nomenclature, we studied an overlapping volcanic structure located south of the present‐day town of Irapuato, Central Mexico, that appears to be a monogenetic complex at first sight. Field observations, tephra stratigraphy, petrography and geochemistry of the tephra deposits confirms that the structure is in fact a cluster of three simple (San Joaquin tuff ring and two scoria mounds) and one complex, polycyclic, polymagmatic (La Sanabria‐San Roque tuff ring) monogenetic volcanoes formed by independent events, governed by distinct conduits and magma bodies of different origin (subduction‐related, OIB and E‐MORB origin) and separated by different tephra sequences of dissimilar components and depositional characteristics. We estimate the magma volumes (using the juvenile content and their vesicularity percentage) to be at 0.40–1.31 × 108, 0.25 × 108 and 0.42–0.90 × 108 m3 for San Joaquin, La Sanabria and San Roque, reckoning an eruption duration of 77 and 48 and 81 days, respectively (considering an average eruption rate of 6 m3/s from the well‐documented shallow crater (<30 m), Ukinrek maars in Alaska) occurring within the age range of 40–70 k years (crater diameter and depth ratio). This study not only aided to validate the above‐mentioned terms for monogenetic volcanoes, but also reconsider a few of them and avoid confusion with the polygenetic counterparts.

Achieving ultra-high efficiency in directed energy deposition of pure copper on Inconel 718 substrate with a 3500 W blue laser

High efficiency deposition of highly reflective copper on a nickel-based superalloy substrate presents a significant challenge. This study first used a 3500 W high-power and 7.5 mm2 large-spot blue laser in Directed Energy Deposition, and successfully deposited copper on an Inconel 718 substrate. The process exhibited stability, with no significant cracks or pores observed. To the best of our knowledge, we have achieved the highest cladding efficiency of 62.84 mm2/s in the current cladding of copper. The interface between copper and Inconel 718 displayed a smooth composition transition at 3500 W, and the width reached 418 μm. The cladding layer displayed a columnar dendritic morphology at the bottom, gradually transitioning to equiaxed dendrites at the top. Dendrites enriched in elements found in Inconel 718 solidified, while Cu from the powder mainly solidified in the interdendritic region. The utilization of a high-power, large-spot blue laser offers a promising process for the efficient fabrication of large Cu/Ni dissimilar structural components.

Computational Insights into Enzyme‐Substrate Binding Interplay Exhibit Variable Binding Attributes: A Framework for Implementing Oxidoreductase‐Based Applications

AbstractLaccase (LAC) is a potent multicopper oxidase that relies on O2 for its catalytic activity. LAC has been affirmed as an environmentally friendly biocatalyst that often catalyzes a wide array of phenolic substrates. Bacterial‐derived LACs have been less investigated for non‐phenolic substrates in contrast to fungi‐derived LAC. To comprehend the substrates (3,4‐Dimethoxybenzyl alcohol, and Dimer (Guaiacyl 4‐O‐5 guaiacyl) binding interactions of LAC (Thermus thermophilus HB27) was carried out and contrasted with fungal‐derived Lignin peroxidase (LiP) (Trametes cervina) exploiting computational methods, including physicochemical properties, Sequence Annotated by Structure (SAS), Extra precision docking (Glide), and DESMOND‐directed MD‐ simulation. Protein structures exhibited by LAC, and LiP have diverse dissimilar component architects. The XP docking suggested LiP‐Dimer seems to have a comparatively lowest binding affinity (−8.413 kcal/mol), with an MMGBSA score of −33.249 kcal/mol. Further, docked complexes were validated leveraging 50 ns NPT system‐based MD‐simulation for structural and functional stability. The system achieved equilibrium and stability at the end of the simulation, with only the LiP‐3,4‐Dimethoxybenzyl alcohol complex maintained stability. The results of this study offer a framework for improving the binding ability of substrates by way of the use of in‐silico protein engineering, which might eventually result in more effective catalytic applications.

Effects of heat treatment on microstructures and properties of a heterostructured alloy with dissimilar components fabricated by WAAM

Effects of heat treatment on microstructures and properties of a heterostructured alloy with dissimilar components fabricated by WAAM

Effect of Chitin Nanocrystal Deacetylation on a Nature-Mimicking Interface in Carbon Fiber Composites

The formation of a rigid, tough interface based on a nacre-like structure in carbon fiber (CF) composites is a promising way to eliminate low delamination resistance. An effective method of coating CFs is electrophoretic deposition (EPD), which, in the case of dissimilar components like graphene oxide (GO) and polymeric glue, usually requires chemical bonding/strong interactions. In this work, we focus on chitin nanocrystals (ChNCs), leading to an excellent mechanical performance of artificial nacre, where favorable interactions and bonding with GO are controlled by degrees of deacetylation (5, 15, and 30%). We prepared coatings based on GO/ChNC adducts with 95/5, 90/10, 50/50, and 25/75 ratios using optimized EPD conditions (pH, concentration, voltage, and time). The prepared materials were characterized using FTIR, TEM, XPS, SEM, DLS, and XRD. SEM evaluation indicates the formation of a homogeneous interlayer, which has a fair potential for chemical bonding with the epoxy matrix. Short-beam testing of epoxy matrix composites indicates that the coating does not decrease stiffness and has a relatively low dependence on composition. Therefore, all coatings are promising for a detailed study of delamination resistance using laminate samples. Moreover, facile EPD from the water solution/suspension has a fair potential for industrial applications.

Laser-directed energy deposition of Ti6Al4V/AA2024 alloy component based on interweaving structure

The presence of brittle intermetallic compounds (IMCs) can easily lead to cracks at the interface of titanium/aluminum alloy components. A novel interweaving structure was proposed and a Ti6Al4V/AA2024 dissimilar alloy component was prepared. The interlocking between Ti6Al4V and AA2024 mitigates the adverse effects of brittle IMCs on the Ti/Al interface, while the interweaving of Ti6Al4V and AA2024 avoids the generation of continuous IMCs. The average compressive shear strength of the Ti6Al4V/AA2024 alloy component is 86.1 MPa, which is 79 % of that of as-deposited AA2024. The fracture occurred in the interweaving layer in shear tests.

Effects of the Number of Layers and Thickness Ratio on the Impact Fracture Behavior of AA6061/AA7075 Laminated Metal Composites

The initial thickness ratio and number of layers of dissimilar metal components greatly influence the impact performance of laminated metal composites. In this paper, positive and lateral impact tests of 5-layer composite sheets with thickness ratios of 3:1, 1.35:1, and 1:2 and 80-layer composite sheets prepared by ARB (accumulative roll bonding) were conducted to study the influences of the thickness ratio and layer number on the impact fracture behavior of composite sheets. The results showed that the higher the proportion of AA7075, the higher the bending strength of the AA6061/AA7075 laminated composite sheet; compared with the 5-layer composite sheet, the side impact performance of the 80-layer composite sheet is obviously improved, and its side impact strength, energy absorbed in the crack initiation stage, and crack propagation stage are better than those of the 5-layer composite sheet. In addition, the toughening mechanism of the 80-layer composite sheet is mainly that the increase in the number of layers makes the cracks deflect more frequently. Under the rapid impact load, the impact energy absorbed by the sample increases with the increase in the number of layers.

Development of functionally graded austenitic lightweight steel through electrically assisted pressure solid-state joining

Functionally graded materials synergistically combine dissimilar components and can be engineered to exhibit gradual controlled variations in composition, structure, or properties, thus featuring advantageous mechanical properties and finding numerous practical applications. However, lightweight functionally graded materials such as those based on lightweight steels (LWSs) remain underexplored, albeit their advancement has significant merit in reducing the overall weight of a component or structure. To address, this study investigates the effective application of austenitic Fe–Mn–Al–C lightweight steels via the fabrication of a functionally graded material, enabling a synergistic combination of their dissimilar properties. Focusing on the mechanical properties of austenitic LWS that can be controlled through κ-carbide precipitation, we propose a novel functionally graded material developed by joining Mo-doped LWS and Si-doped LWS, which exhibit different κ-carbide precipitation behaviors. Electrically assisted pressure joining, an effective solid-state joining technique capable of enhancing atomic diffusion, was employed to strongly bond two dissimilar LWSs with improved joint integrity while preserving a homogeneous austenite matrix at the joint. Mechanical and microstructural characterization demonstrated that a high-quality and reliable solid-state joint was achieved within a short timeframe of a few minutes without elemental segregations and phase transformations in the metal matrix. The opposing tendencies of Mo to retard the κ-carbide kinetics and Si to enhance it resulted in two divided regions: a Mo-doped low hardness zone and a Si-doped high hardness zone in the joined LWS. Furthermore, by exploiting carbon diffusion driven by the chemical potential gradient, we successfully attained remarkable gradients in the amount of κ-carbide precipitate and hardness, from the joint interface to the Si-doped high hardness region. These findings manifest the applicability of the suggested technique in the meticulous design of functionally graded LWS joint materials.

Numerical simulation and experimental study of residual stress in dissimilar aluminum alloy laser composite welding

The study combined experimental and numerical simulation methods to investigate the distribution of residual stress in laser composite welding of dissimilar aluminum alloys 6063 and 5083. Using the Simufact Welding simulation software and a combined volume heat source, the distribution patterns of transverse and longitudinal residual stress fields at different welding speeds were analyzed. The blind hole method was used to test the residual stress after welding. The results showed that the use of a combined volume heat source model for heat source calibration yielded ideal results, and the thermal cycle curve was basically consistent with the simulation and experimental results of residual stress. As the welding speed decreased, the longitudinal residual stress of the parent material on both sides significantly decreased, while the transverse residual stress increased. The majority of tensile and compressive stresses on both sides of the 5083 and 6063 aluminum alloys decreased with a decrease in welding speed. The Von Mises equivalent stress indicated that the cooling process is the main stage for residual stress generation. When the welding speed decreased, the peak value of longitudinal residual stress on the 6063 aluminum alloy side decreased from 230 to 90 MPa, while that on the 5083 aluminum alloy side decreased from 304 to 150 MPa. These findings provide an important basis for controlling and reducing the residual stress and deformation of dissimilar aluminum alloy laser arc composite welded components.

Effect of nickel interlayer on laser welding of copper/titanium dissimilar metal joint

Cu/Ti dissimilar metal welding components have significant potential applications in aerospace, nuclear industries, and other fields. To achieve a robust connection between titanium (TA2) and copper (T2), this study conducted laser-welding experiments using nickel as an intermediate layer. The influence of a nickel intermediate layer on the joint formation, microstructure, mechanical properties, melting, and element diffusion behavior were investigated. The results revealed that without the addition of a nickel intermediate layer, when the laser beam was biased toward the titanium side during welding, a 17 μm thick layer of intermetallic compounds formed in the copper-side weld region. In this area, a notable concentration of fragile Ti–Cu intermetallic compounds forms, rendering it the weakest point in the joint. As a consequence, the ultimate tensile strength of the joint measures at 131 MPa, which is roughly 55 % of the tensile strength of the copper base material. The introduction of a nickel intermediate layer led to a change in the microstructure of the fusion zone, with Cu–Ti intermetallic compounds dispersed within, preventing the formation of brittle Ti–Cu phases at the copper interface. The addition of the nickel interlayer increased the tensile strength of the TA2-T2 joint to 224 MPa, which is approximately 94 % that of the copper parent material, and the joint exhibited ductile fracture behavior in the copper parent material's heat-affected zone.

Functionally graded deposition of dissimilar steel (316LSi and ER70S-6) fabricated through twin-wire arc additive manufacturing

Fabrication of dissimilar steel-based (SS316LSi over ER70S-6 steel) functionally graded deposition (FGD) using twin wire arc additive manufacturing (T-WAAM) via a unique deposition strategy is investigated in this work. Optical, SEM, EDS, X-ray diffraction (XRD), tensile, hardness, and fractography analyses were undertaken for complete microstructural and mechanical characterisation. Microstructural analysis revealed columnar, equiaxed, and cellular dendrites in δ-ferrite and austenitic phases. XRD investigation depicted the anisotropic behaviour of specimen textures in various planes. The estimated value of average ultimate tensile strength is 901 MPa, yield strength (YS) is 634 MPa, and percentage elongation (EL%) is 48 %, respectively. This work offers a novel strategy for producing superior-strength dissimilar steel components with excellent quality and varied structural utility.

Investigation on the microstructure and mechanical property of friction stir lap welded acrylonitrile butadiene styrene/polycarbonate produced by double-pin tool

Friction stir lap welding (FSLW) of dissimilar acrylonitrile butadiene styrene (ABS) and polycarbonate (PC) was conducted using a double-pin tool. The formation process of the weld and the influences of rotational speed on the microstructure and mechanical property were investigated. It was found that the weld was generated accompanying with the closure of old cavities in the front of the pins and the simultaneous regeneration of new cavities in the rear of the pins. Annular material flow on the vertical and horizontal directions occurred during FSLW. With the increase of the rotational speed, the PC anchors resulted from the upflow of plasticized PC layer and the shoulder affected zone both enlarged. Microstructure analysis of the weld nugget showed that PC was fragmented into lamellar, columnar, and spherical particles and their dimensions decreased when rotational speed increased. Lap-shear tensile tests showed that the weld strength increased with higher rotational speed and the maximum strength of the weld produced under 800 r/min reached 19.38 MPa, which was comparable to the ABS/PC welds produced by a tapered pin under the optimal parameters. Through the further optimization of such FSLW process, it was potential to join dissimilar polymeric components in future industrial manufacturing field.

Fatigue Behavior of Rotary Friction Welding of Acrylonitrile Butadiene Styrene and Polycarbonate Dissimilar Materials.

Understanding the fatigue behaviors of weld joints is significant in engineering practice. Rotary friction welding (RFW) can join the additively manufactured polymer components. Until now, no research has focused on the fatigue behavior of polymer components jointed via RFW. This study investigates the fatigue life of ABS/PC dissimilar components fabricated via RFW and proposes the fatigue mechanism based on the failure structure. This work uses five different cyclic loads and rotational speeds to investigate the fatigue life. The fatigue life of the RFW of ABS/PC dissimilar rods is better compared with the pure ABS and pure PC specimens due to weld and integrity microstructural changes resulting from the combination of ABS and PC materials. The number of cycles until the rupture of RFW of ABS/PC dissimilar components (y) can be determined by the cyclic load (x) according to the prediction equation of y = -838.25x2 - 2035.8x + 67,262. The fatigue life of the RFW of ABS/PC dissimilar components increase with the increased rotational speed. The number of cycles until rupture (y) can be determined by the different rotational speeds (x) according to the prediction equation of y = 315.21x2 + 2710.4x + 32,124.

Electrically Conductive Liquid Metal Composite Adhesives for Reversible Bonding of Soft Electronics

AbstractConductive adhesives are required for the integration of dissimilar material components to create soft electronic and robotic systems. Here, a heterogeneous liquid metal‐based conductive adhesive is developed that reversibly attaches to diverse surfaces with high stretchability (>100% strain), low modulus (<100 kPa), and strain‐invariant electrical conductivity. This SofT integrated composite with tacK through liquid metal (STICK‐LM) adhesive consists of a heterogeneous graded film with a liquid metal‐rich side that is embossed at prescribed locations for electrical conductivity and an electrically insulating adhesive side for integration. Adhesion behavior is tuned for adhesion energies > 70 Jm−2 (≈ 25x enhancement over unmodified composites) and described with a viscoelastic analysis, providing design guidelines for controllable yet reversible adhesion in electrically conductive systems. The architecture of STICK‐LM adhesives provides anisotropic and heterogeneous electrical conductivity and enables direct integration into soft functional systems. This is demonstrated with deformable fuses for robotic joints, repositionable electronics that rapidly attach on curvilinear surfaces, and stretchable adhesive conductors with nearly constant electrical resistance. This study provides a methodology for electrically conductive, reversible adhesives for electrical and mechanical integration of multicomponent systems in emerging technologies.

Achieving high-temperature thermal evacuation between dissimilar materials Cf/C and Mo30Cu by forming a brazed joint

Achieving a high heat transfer is essential for the Cf/C-Mo30Cu dissimilar material components in their applications of thermal nuclear reactions. In this study, the Cf/C composite and the Mo30Cu alloy were successfully brazed by using the Ag-Cu-4.5Ti braze to eliminate interface gaps between them. The maximum thermal conductivity of the Cf/C-Mo30Cu joint at 860 °C /10 min reached 112 W·m−1·K−1(RT). The thermal conductivity of the joint even exceeds that of the Cf/C matrix (107 W·m−1·K−1). It is worth noting that the overall thermal conductivity of the joint can still reach 92 W·m−1·K−1 at 500 °C. Shear test results showed that the average shear strength of the joints achieved 13.1 MPa at the highest thermal conductivity of the joint. A homogeneous TiC layer is generated along the Cf/C interface, which is crucial for maintaining a stable joint and providing a favorable heat transfer channel across the Cf/C-Mo30Cu dissimilar materials.