Dissimilar Materials Research Articles

Investigation of Laser Surface Texturing and Injection Molding Parameters in Advanced High‐Strength Steel‐Polyamide Direct Joining

This study investigates the joining of dissimilar materials, specifically galvannealed advanced high‐strength steel (AHSS) and glass fiber‐reinforced polyamide 6 (PA 6) to achieve lightweight automotive. AHSS and PA 6 are widely used in the automobile industry; however, a direct joining of those two materials is difficult owing to their great difference in physical properties. Therefore, laser surface texturing (LST) and plastic injection molding are adopted to join AHSS and PA 6, which can create a strong mechanical interlock between AHSS and PA 6, resulting in an excellent joint strength compared to other joining techniques. The effects of LST parameters (groove depth and hatch distance) and injection molding temperatures on the joint strength are examined. The maximum AHSS‐PA 6 joint strength is measured at 72.3 MPa. Additionally, the microstructure and mechanical properties of recast, which develops over the original metal surface by melting and resolidifying, are analyzed. Compared to the base metal, the recasts exhibit higher hardness due to smaller grain sizes. PA 6 fills the laser‐textured grooves and spaces between the recasts, acting as a mechanical interlock that enhances joint strength under tensile shear testing.

Investigation of Electromagnetic Wave Propagation in Photonic-like Welded Materials Using the Finite Element Method

In this study, two identical and two dissimilar materials are conjoined by applying the friction welding method to yield various rods. This investigation’s primary focus entails examining the repercussions associated with the heat-affected zone (HAZ) arising from elevated temperatures at the welding interfaces on the propagation of electromagnetic (EM) waves within the resultant structures. The study incorporates the photonic crystal approach in conjunction with Maxwell’s equations, and the subsequent solution of the latter is executed using the finite element method. The subdivision of the structures into fifteen elements is predicated upon the assumption of the electromagnetic wave number of the m-th segment, km, of discrete segments. The finite element method is then administered to the HAZ regions of the structures, wherein the HAZ is discretised into one, three, and five elements, respectively.

Slip-pulses drive frictional motion of dissimilar materials: Universality, dynamics, and evolution

Frictional slip between bodies having different elastic or geometrical properties (bimaterial interfaces) creates a unique type of rupture, bimaterial "slip pulses." These slip pulses propagate along the interfaces separating elastically different contacting bodies. They exhibit highly localized slip with accompanying local normal stress reduction. These pulses do not result from properties of "friction laws" but, instead, are formed via the elastic mismatch of the contacting bodies. Here, we experimentally study slip pulse dynamics, evolution, and structure in seven different bimaterial interfaces. We find that slip pulses are a major vehicle for frictional motion in bimaterial interfaces, they exist in well-defined velocity windows and undergo unstable growth consistent with theoretical predictions coined the "Adams instability." When scaled properly, slip pulses exhibit both universal spatial structure and growth dynamics. While slip pulse amplitudes vary considerably within different interfaces, this variation is, surprisingly, not highly dependent on the contrast of the elastic properties of the contacting materials. Instead, slip pulse amplitudes are closely related to the interfaces' aging properties and, hence, to material plasticity at the interface. As bimaterial interfaces are generic, these results are fundamentally important to both frictional dynamics and the dynamics of earthquakes within a wide class of natural faults.

Reinforcement and toughening of the self‐piercing riveted bonded joints induced by the pre‐embedded adhesive in rivet cavities

AbstractSelf‐piercing riveted bonded (SPRB) joints are widely used in body‐in‐white (BIW) to connect dissimilar materials owing to their high fatigue and electrochemical performance. However, the strength of the SPRB joint has been found to be inferior to that of self‐piercing riveted (SPR) joints, owing to the reduction in undercut induced by the introduction of an adhesive, especially under pull‐out loading conditions. Interestingly, the mechanical strength improved when the rivet cavity was pre‐embedded with an adhesive. Before the riveting process, the rivet cavities in SPRB joints were pre‐embedded with 0.01, 0.02, and 0.03 mL of adhesive, namely them PSPRB‐V1–V3, respectively. Finite element (FE) models of SPRB and PSPRB joints were developed to analyze their formability and mechanical properties. The simulated and experimental results showed that the hydraulic pressure in the rivet cavity increased as the pre‐embedded adhesive volume in the rivet cavity increased during the riveting process, which further improved the undercut, microhardness, effective bearing area, and mechanical properties of joints. Among the prepared PSPRB joints, the PSPRB‐V3 joint exhibited the best undercut and optimal mechanical properties. Specifically, its undercut and peak force increased by 16.43% and 12.87% compared with those of SPRB joints. These findings provide important guidance for designing steel‐aluminum SPRB joints that require high‐bearing capabilities.Highlights The effect of pre‐embedded adhesive on the SPRB joint cross‐section was studied. Failure mechanisms of the SPRB and PSPRB joints were investigated via FEM. The better PSPRB joint performance over SPRB joints was elucidated. The stress–strain history was considered in the FE model of the joint failure process. Strengthening mechanism of pre‐embedded adhesive in the rivet cavity was discussed.

Direct laser active brazing of 316Ti to alumina

AbstractThis work addresses the challenges in brazing thermohydraulic sealings involving dissimilar materials, specifically 316Ti stainless steel and alumina, which have significantly different coefficients of thermal expansion (CTEs) and elastic constants. Traditional brazing methods require complex interlayers or extensive metallization steps, leading to issues such as dimensional changes, braze voids, and inadequate corrosion resistance due to prolonged high‐temperature exposure. A novel laser‐based brazing technique utilizing a diode laser is introduced to create high‐quality, localized joints while preserving the integrity of the parent materials. The study systematically optimizes laser process parameters using finite‐element modeling and the Taguchi method to achieve the desired bead geometry and thermal stress distribution with minimal heat input. Comparative analysis between laser active brazing (LAB) and conventional furnace brazing was conducted through metallography, shear testing, and autoclave testing. Results indicate that LAB parameters significantly affect bead thickness and shear strength, with laser‐brazed joints demonstrating superior quality and stability post‐autoclave testing compared with furnace‐brazed joints. The thermodynamic and kinetic aspects of the brazing process were also analyzed. In conclusion, the LAB method for brazing 316Ti to alumina proves to be a successful and efficient alternative, with joint properties meeting or exceeding those of traditional furnace brazing.

Examination of Microstructure, Mechanical Properties, and Fatigue Strength in a Wire Arc Additively Manufactured Material Comprising Dissimilar Materials: AISI 316L Stainless Steel and Carbon Steel

This study provides a comprehensive investigation into the microstructure, hardness, tensile strength, and bending fatigue behavior of a Wire Arc Additively Manufactured (WAAM) component composed of dissimilar materials—Carbon Steel (CS) and 316L stainless steel. Microscopic analysis reveals distinct microstructural characteristics, such as equiaxed ferrite grains in WAAM CS and a coarse columnar structure with delta-ferrite phases in WAAM 316L. A macroscopic phase map indicates a predominantly Body-Centered Cubic (BCC) structure near the interphase, suggesting element migration between CS and 316L due to high heat input. Higher magnification scans highlight martensitic structures on both sides of the interphase, with the CS side exhibiting larger grain sizes. Hardness assessment along the built direction shows a peak hardness of 407 HV near the interphase on the 316L side, contrasting with the CS side's average interphase hardness of 316 HV due to larger grain sizes. The yield strength of both WAAM CS and WAAM dissimilar material was consistently measured at 392 MPa. In comparison, WAAM 316L exhibited a slightly lower yield strength of 359 MPa. Notably, WAAM 316L demonstrated the highest tensile strength among the materials, reaching 656 MPa. Meanwhile, WAAM CS displayed a robust tensile strength of 503 MPa, and the WAAM dissimilar material exhibited a yield strength of 520 MPa. In terms of elongation, WAAM CS and WAAM 316L showcased values of 44.9% and 49.6%, respectively. On the other hand, WAAM dissimilar material exhibited a somewhat lower elongation of 20.4%, suggesting a different mechanical behavior in terms of ductility. Bending fatigue tests on WAAM 316L, WAAM CS, and the dissimilar material reveal a fatigue limit of approximately 225 MPa for WAAM 316L, 210 MPa for WAAM CS, and approximately 210 MPa for the dissimilar material. In the low-cycle and medium-cycle regimes, the dissimilar material exhibits slightly superior fatigue strength, potentially due to its marginally higher static strength. Notably, consistent fractures on the CS side during fatigue tests underscore a recurring behavior in the dissimilar material.

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.

Enhanced interfacial joining strength of joined high chromium gray cast iron/low carbon steel joint via graphite coating

Liquid-state bonding is one of the most crucial methods in joining dissimilar materials to manufacture composites with structural design. The high chromium gray cast iron (HCGCI)/low carbon steel (LCS) composite structure is attractive in mining industries due to its superior mechanical properties and low density. However, the decarburization of the faying surface of HCGCI leads to the formation of a coarse-grained brittle interlayer between HCGCI and LCS which seriously deteriorates the mechanical properties of welded joints. In this work, high chromium gray cast iron/low carbon steel composite was fabricated by diffusion bonding via graphite coating layer. The results showed that the graphite coating on the fusion surfaces prevented the decarburization of HCGCI and the growth of coarse grains which improved the bonding quality. The ultimate tensile strength and total elongation of the graphite-free sample are 335.6 MPa and 8.9%, respectively. In contrast, the ultimate tensile strength and total elongation of the graphite-contain sample are 435.6 MPa and 17.9%, separately. This work opens a new strategy for fabricating high chromium gray cast iron/low carbon steel composite, and the flexibility to achieve complex structures through liquid-state bonding is extended.

Characteristics of Solidification Cracking for Ni-P Coated Cu-Al5052 Single-Mode Fiber Laser Welds

This study fundamentally examines the characteristics of solidification cracking in Cu-Al5052 single-mode fiber laser welding by utilizing uncoated and Ni-P coated Cu plates for the high durability busbar welding of pouch-type lithium-ion battery packs. Weld solidification cracking was confirmed regardless of Ni-P coating for both weld materials. However, there were differences in the regions of crack occurrence. Unlike the uncoated Cu-Al5052 welds where cracks occurred randomly within the fusion zone, for the Ni-P coated Cu-Al5052 welds, solidification cracks were concentrated near the faying surface of the upper and lower materials, particularly near the fusion line. The effect of the Ni and P components on the solidification cracking susceptibility, i.e., the welding solidification temperature range, was considered. Diffusion-controlled Scheil’s solidification calculations revealed that the mushy zone range enlarged with the use of a Ni coating layer. It was confirmed that an extremely wide mushy zone range of 1060 K was calculated at the solidification cracking region. Furthermore, P was also identified as an element that expands the solidification temperature range based on the Cu-P binary system. Consequently, during the laser welding of Cu-Al5052 dissimilar materials, the behavior of solidification cracking in the welds is influenced by the composition of the coating material and the incorporated composition within the weld fusion zone. Hence, it is necessary to select the optimal coating material and layer thickness considering weld solidification cracking susceptibility.

Demonstration of efficient Thomson cooler by electronic phase transition.

In the 1850s, Lord Kelvin predicted the existence of a thermoelectric cooling effect inside a whole material (the Thomson effect) according to thermodynamics1, in addition to the Peltier effect that enables cooling at the junction between dissimilar materials. However, the Thomson effect is usually negligible (ΔT/T < 2%) in conventional thermoelectric materials because the entropy change in charge carriers is fairly small2, leading to the guiding principles for advancing thermoelectric cooling to be based on the framework of the Peltier effect and that the figure of merit ZT should be maximized to optimize performance. Here, we demonstrate a Thomson-effect-enhanced thermoelectric cooler using a large Thomson coefficient (τ) induced by the direct manipulation of charge entropy through an electronic phase transition in YbInCu4. The devices achieve a steady temperature span (ΔT) of >5 K from T = 38 K. Our findings suggest not only another approach to advance thermoelectric coolers in addition to improving ZT but also technologically opens opportunities for solid-state cryogenic cooling applications.

Experimental and numerical study of dissimilar fiber laser welding of martensitic AISI 1060 carbon steel with different configuration with austenitic 304 and ferritic 420 stainless steel

Welding with fiber laser for two distinct stainless steel types was performed to join with the martensitic carbon steel (AISI 1060) in order to assess the effect of laser welding operating parameters for two dissimilar materials on the weld characterization thorough experimental design method and numerical investigation. A full central composite design (CCD) matrix in accordance with the response surface methodology (RSM) was developed to represent the responses variations by equations including quadratic and nonlinear interaction terms. Different laser welding parameters were taken into account, such as laser power, linear speed of welding, focal distance of the beam, and beam deviation. The responses considered were the temperature field next to the melt pool border line, the maximum penetration depth of the fusion zone and the ultimate tensile strength of the dissimilar weld joint. Additionally, the variation of the microstructure fusion zone and adjacent areas and failure mechanism of the weld joint were evaluated. The experimental results indicate that the temperature field measured at the vicinity of the melt pool fusion line with both 304 and 420 stainless steel which primarily influenced by the incident power of the laser and linear velocity of beam, respectively. Additionally, the numerical simulation results are in good agreement with temperature experimental results at vicinity of fusion line where the temperature measured, experimentally. Apart from this, at the center of the fusion zone, the temperature clearly predicts via numerical simulation results which is not possible to assess experimentally. A clear comparison between the temperature distribution with different joint configuration illustrates that distinct relation between the temperature variation rate and different thermal conductivity coefficient of AISI 1060 with different AISI 304 and 420 joint configuration resulted different temperature distribution. The weld joint microstructure for 420 stainless steel–AISI 1060 steel joint at fusion boundary zone consists of columnar dendrites and skeletal columnar ferrite. At the center of fusion zone, a cellular-type structure is seen. For 304 stainless steel joint, the fusion zone has composed of a remarkable part of skeletal delta-ferrite and dendritic microstructure at austenite matrix microstructure. The fracture section of 304 steel has a ductile fracture and the depth of fracture dimples and cavities toward 304 stainless steel are higher than AISI 1060 steel.

Parametric investigation of friction stir welding of aluminum alloy and Inconel 718 using finite element analysis

Friction Stir Welding (FSW) has emerged as a prominent technique for joining metallic materials, offering advantages in both similar and dissimilar material combinations. Despite its effectiveness, further advancements are needed to address industry demands and enhance the understanding of the FSW process. Welding nickel-based superalloys like Inconel 718 poses specific challenges, with existing literature suggesting that achieving successful welds requires high axial forces and precise process parameters, limiting its practical application in industries. To tackle these issues, this research proposes the utilization of 3D finite element models integrating multiphysics aspects, encompassing material flow and heat transfer mechanisms such as conduction, convection, and radiation. These models were validated against existing experimental data and employed to analyze temperature and strain distributions within the heat affected zone and weld nugget. The findings offer insights into the impact of various process parameters, including rotational speed, welding speed, normal force, cooling rate, and the effect of induction preheating, on key performance metrics like temperature profiles, grain size distribution, microhardness, and stress evolution. The outcomes underscore a notable correlation between process variables and performance indicators, facilitating a comprehensive understanding of the FSW process dynamics.

Formation and strengthening mechanism of high entropy nugget for aluminum/steel resistance rivet welding

Resistance rivet welding (RRW) was a promising joining process for aluminum (Al) alloy and steel. The high entropy mixed nugget (HEMN) with the composition of Al0.8CoCrFe1.6Ni was obtained by introducing a high entropy alloy (HEA) rivet in RRW process. The high entropy played a significant role in facilitating the formation of solid solution. The HEMN microstructure exhibited a nanometer-sized weave-like structure caused by spinodal decomposition, comprising both BCC and B2 phases. The average hardness of the HEMN exceeded that of the Al/Steel mixed nugget, resulting in higher lap-shear strength and ductility. The analysis of strengthening mechanism demonstrated that the lattice misfit and order strengthening were the primary contributors. This study provided a novel strategy for joining dissimilar metal materials.

Application of energy, electronic and interface bonding properties in highly reliable brazing joints between dissimilar materials

Application of energy, electronic and interface bonding properties in highly reliable brazing joints between dissimilar materials

Novel approach for in-line process monitoring during ultrasonic metal welding of dissimilar wire/terminal joints based on the thermoelectric effect

AbstractUltrasonic metal welding (USMW) is a manufacturing technique widely employed in the automotive and aerospace industries due to its efficiency in joining similar as well as dissimilar metals. Despite its prevalence, the lack of effective in-line process monitoring methods has resulted in high scrap rates, product recalls due to unrecognized scrap or financial losses due to pseudo-scrap, limiting its application in more sensitive industries. This paper presents a novel thermoelectric effect-based method for in-line process monitoring of USMW processes. This approach utilizes the thermoelectric properties, that manifest at the junctions of dissimilar metals during welding to accurately measure the temperature of the weld zone without the need of additional thermocouples, pyrometers or infrared cameras. An experimental setup was developed to validate the thermoelectric-based temperature measurement methodology. Key to this approach is the detection of thermoelectric voltage developed due to thermo diffusion when dissimilar materials are joined. The experiments showed a strong correlation between the thermoelectric voltage and the mechanical strength of the welds, suggesting that this parameter can effectively predict the quality of the weld. In the trials, a series of welded samples was created under controlled conditions to measure the generated thermoelectric voltage and correlate it with ultimate tensile strength tests. The data were analyzed using Spearman’s correlation coefficients to determine the correlation of the thermoelectric signals and joint strength. Results indicate that the thermoelectric voltage measurements correlate highly with the joint strength, with a Spearman’s correlation coefficient of over 0.94, thereby providing a promising predictive metric for assessing weld quality.

A comparative study of friction stir welding and friction stir scribe technique for dissimilar metal joining

Abstract Friction stir welding (FSW) has emerged as a novel method for joining similar and dissimilar ferrous and non-ferrous materials. This solid-state welding process utilizes frictional heat generated between a tool shoulder and the base material. The stirring action facilitates the movement and consolidation of the material, resulting in localized fusion and the formation of a joint. This review examines their effectiveness in joining various material combinations, with particular focus on automotive and aerospace applications. FSW utilizes frictional heat and stirring action to create localized plasticity and material flow, while FSS incorporates a cutting feature to mechanically interlock dissimilar materials. The review paper shows comparison of various experimental investigations considering variables such as tool geometry, welding parameters, and material combinations. FSW has some significant parameters to enhance weld quality such as traverse speed, plunge depth, and tool design. These techniques show promising applications for multi-material integration, offering advantages over conventional fusion welding methods. Future research directions include expanding material combinations, developing automated systems, and exploring hybrid joining approaches.

Finite element simulation investigation of warping deformation during baking temperature cycle of dissimilar materials sandwich adhesive bonded structures of car body

Adhesive bonding is crucial for joining lightweight, mixed-material car bodies but can cause distortion due to changes in adhesive properties during heat curing. In this paper, based on the characteristics of the roller-hemming structures, a sandwich adhesive bonded structure of aluminum-steel dissimilar materials was designed. A viscoelastic model for the hemming adhesive was developed, and a coupled thermal-chemical-structural model was implemented in ABAQUS. Baking experiments validated the model. Stress and strain variations were analyzed to understand warping mechanisms during the temperature cycle. Further analysis results showed that decreasing heating rate, holding temperature, or increasing cooling rate can reduce deformation.

Shaping the mechanical properties of a gelatin hydrogel interface via amination.

Injuries to musculoskeletal interfaces, such as the tendon-to-bone insertion of the rotator cuff, present significant physiological and clinical challenges for repair due to complex gradients of structure, composition, and cellularity. Advances in interface tissue engineering require stratified biomaterials able to both provide local instructive signals to support multiple tissue phenotypes while also reducing the risk of strain concentrations and failure at the transition between dissimilar materials. Here, we describe adaptation of a thiolated gelatin (Gel-SH) hydrogel via selective amination of carboxylic acid subunits on the gelatin backbone. The magnitude and kinetics of HRP-mediated primary crosslinking and carbodiimide-mediated secondary crosslinking reactions can be tuned through amination and thiolation of carboxylic acid subunits on the gelatin backbone. We also show that a stratified biomaterial comprised of mineralized (bone-mimetic) and non-mineralized (tendon-mimetic) collagen scaffold compartments linked by an aminated Gel-SH hydrogel demonstrate improved mechanical performance and reduced strain concentrations. Together, these results highlight significant mechanical advantages that can be derived from modifying the gelatin macromer via controlled amination and thiolation and suggest an avenue for tuning the mechanical performance of hydrogel interfaces within stratified biomaterials.

Development of an Artificial Neural Network Model to Predict the Tensile Strength of Friction Stir Welding of Dissimilar Materials Using Cryogenic Processes

Development of an Artificial Neural Network Model to Predict the Tensile Strength of Friction Stir Welding of Dissimilar Materials Using Cryogenic Processes

Highly reliable joints between dissimilar materials

Highly reliable joints between dissimilar materials