Metal Joining Research Articles

Joining UFG Copper by Means of the W2Mi Machine

Joining metals with ultra-fine grains (UFG) is very difficult. UFG metals have a grain size of less than 1 µm. Exceeding the recrystallization temperature causes the growth of ultra-fine grains and degradation of the material’s mechanical properties. The process temperature is influenced by the amount of energy supplied to the joint, which depends on the power and time. Conventional machines are not adapted to effectively conduct the process in extremely short friction times. For this reason, this article presents the welding process on the W2Mi prototype machine. The design of this machine allows the joining of UFG metals in less than 100 ms. UFG material produced using the hybrid SPD (Severe Plastic Deformation) process from technically pure CW004A(Cu-ETP) copper was used for welding tests. The joint obtained on the W2Mi machine did not show any significant degradation signs of mechanical properties. At the same time, an increase in microhardness in the joint area by approximately 4% was noticed. The obtained results prove that the process of joining UFG metals was successfully carried out.

Numerical simulation of temperature distribution and residual stress in TIG welding of stainless-steel single-pass flange butt joint using finite element analysis

Abstract Controlling defects such as deformation in the weld joint and the residual or superfluous stresses due to tungsten inert gas (TIG) welding or arc welding is a major concern for many industries like aeronautical, automobiles, nuclear or atomic power plants, crude oil or fossil fuel industries where pipes are in use and circumferential welding is done. Arc welding is a metal joining process, and TIG welding is applied to many industrial sectors that require high-quality welding. Simulation has been done on single-pass TIG welding on the Flange pipe of SS316 to evaluate transient temperature, residual stresses, and distortion. First, a 3D model is developed and assembled in SolidWorks. Second, in an MSC Patran, preprocessing of the FE model is done. Finally, in MSC Marc, thermal and mechanical simulation is performed. Based on this simulation, the accuracy of welding of the flange–butt joint made of SS316 is validated. In this study, the information regarding simulation of temperature dispensation and residual or superfluous stresses is done on the flange–butt joint, and it found the stresses are compressive at the weld bead area, and along the transverse direction, stresses changed to the tensile. The experimental data show that the steep curve at 0.00 mm represents a maximum temperature near the weld path at approximately 2,352°C, and the slant curve shows the far away points from the weld path. Comparing it with FE analysis, the maximum temperature attained was around 2,539°C. An approximate deviation of 7.365% was observed. The results of the study will provide experimental and simulation analyses for the welding of pipes of stainless steel for the transportation of oil and gases in the petroleum industries.

Interface Characterization of Fusion Bonded Composites Made from Laser-Pretreated Steel and Glass Fiber-Reinforced Thermoplastics Using Electrochemical Impedance Spectroscopy

Material-hybrid designs made of metal and plastic are becoming increasingly important in the automotive and aerospace industries. They place new demands on joining technology in particular. One promising process is the fusion bonding of metals and fiber-reinforced thermoplastics. In this process, the thermoplastic matrix material of the fiber-reinforced composite component is melted and a direct adhesive bond is created with the metallic joining partner. This joining technology has already been extensively studied in the past. In particular, the interface between the joining partners has been identified as a critical factor for the long-term quality of the joint. The interface can be altered by influences during production, such as e-coat process or the effects of harsh environmental conditions during operation like corrosion and thermomechanical loads. Determining the extent of these influences on the interface condition and thus the quality of the joint is difficult, but it is essential to support the use of the joining method in safety-critical areas. Previous investigations of this joining method have mostly been carried out destructively using tensile shear tests and non-destructively using fiber optic and piezo ceramic sensors, but all approaches have only shown limited significance with regard to the metal-plastic interface in detail. Electrochemical impedance spectroscopy (EIS) as a very sensitive measurement method could represent an almost non-destructive and at the same time very sensitive alternative which is currently not reported for this use case in the literature. In previous internal investigations, we found that EIS can be used to measure layer thicknesses of up to 3.5 mm, contrary to the usual use of this test method for characterizing the properties of thin coatings, corrosion behavior and battery performance. In fusion bonding applications, typical material thicknesses of thermoplastics above the interface are around 1.5 mm and are thus well above the usual layer thicknesses of approx. 20 µm to 100 µm for typical EIS applications. This study aims to examine how EIS can be used advantageously for the interface characterization of fusion bonded specimens and up to which extent the EIS can provide a statement about the metal-plastic interface. In this study, a joint of a laser-pretreated steel and a glass fiber-reinforced PA6 is investigated. We measured specimens directly after production, after a treatment similar to an automotive e-coat process and after certain intervals of a salt spray test. Using the Kramers-Kronig transformation, the EIS data was validated and qualitatively analyzed with Nyquist and Bode diagrams, the impedance at 0.1 Hz, the maximum impedance and equivalent circuits. Tensile shear and edge shear test serve as destructive reference tests to determine strength parameters of the joints and evaluate the respective fracture patterns. This opens up the possibility to correlate the results of EIS and destructive measurements. In summary, EIS is suitable for characterizing the metal-plastic interface, even with polymer thicknesses of 1.5 mm, which are comparatively high for EIS. Due to the very low phase angle and the resulting low dielectricity of the glass fiber-reinforced thermoplastic, changes in the impedance data are directly related to the interface condition. The measured impedance spectra could be differentiated with Nyquist and Bode diagrams, the impedance at 0.1 Hz and the maximum impedance.

A Review on Joining of Dissimilar Metals with Highly Differential Thermomechanical Properties

A Review on Joining of Dissimilar Metals with Highly Differential Thermomechanical Properties

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.

Optimization of TIG welding process parameters using Taguchi technique for the joining of dissimilar metals of AA5083 and AA7075

This research paper aims to optimize the TIG welding parameters to join dissimilar metals of AA5083 and AA7075 using the Taguchi technique. The TIG welding current and root gap of butt geometry configuration are considered input parameters, and welding characteristics such as tensile strength, 0.2% of yield strength, hardness, and impact energy are output responses. The base metals are joined according to the Taguchi L-09 design of experiments. The welded samples were inspected using the X-ray radiography method for internal defects. Tensile properties, hardness number, and impact energy of different welding coupons were evaluated by conducting the uni-axial testing, a Brinell hardness test, and an Izod impact test, respectively. A better weld strength of 224 MPa was observed at 210 A welding current, and the root gap of 1.5 mm was maintained. Better hardness and impact energy values were observed when the root gap of 1.5 mm and welding current of 220 A were maintained. The root gap is the primary factor influencing tensile strength enhancement, which accounts for 44.78% of the effect, followed by 40.5% welding current. Root gap is the parameter that affects the tensile properties, hardness number, and impact toughness the most. The findings of this paper suggest the optimal parameters for welding AA5083 and AA7075 dissimilar base metals, which are suitable for complex structures requiring both durability and resistance to harsh environments.

Dissimilar joining of Ti–6Al–4V to 316L stainless steel by a novel joining process based on arc additive manufacturing and combined twin-wire arc welding

The joining structure of Ti–6Al–4V to 316L stainless steel has potential demands in many fields. However, it is very difficult to avoid the formaiton of intermetallic compounds (IMCs) of the weld between Ti–6Al–4V to 316L stainless steel, which will severely decrease joint properties. In this paper, a novel joining technology that combines the single wire backing arc welding and the spatially arranged combined twin-wire arc welding was utilized to join Ti–6Al–4V and 316L stainless steel. Copper alloy wire (S214) and vanadium alloy wire (V01) were used as filler metals to produce two isolation layers, which prevented the formation of IMCs. The phase compositions at the Fe/Cu, Cu/V and V/Ti interfaces were Fe(S,S) + Cu(S,S), Cu(S,S) + V(S,S) and V(S,S)+(β-Ti, V)SS respectively. The distribution of the spherical and clustered V(S,S) particles in the matrix at the Cu/V interface contributes to dispersion strengthening and solid solution strengthening of the interface. Tensile strength of 394 MPa with an elongation of 2.53% was achieved. The joint fractured at the Cu/V interface of the single wire backing arc weld and the Cu zone of the spatially arranged combined twin-wire arc weld respectively. Dimple plastic fracture modes were detected in the joints. This technology is not only applicable to Ti–6Al–4V titanium alloy/316L stainless steel dissimilar metal joining, but also provides a new research strategy for the joining between other dissimilar metals.

Research on Direct Joining of Metal and Thermoplastic Resin Using Laser Structuring and IH Heating

Research on Direct Joining of Metal and Thermoplastic Resin Using Laser Structuring and IH Heating

Role of Activating Flux in Weld Bead Symmetricity during Dissimilar Metal Joining

Ferritic/martensitic steels and austenitic stainless steels are high‐strength steels, and highly recommended in high‐temperature and high‐pressure application. In general, multimetallics with different Inconel alloys are used for joining. This is quite a complex and time‐consuming procedure. The current work demonstrates the efforts made to weld 8 mm‐thick P91 steel and 316L SS plates in a single pass using activating flux tungsten inert gas (A‐TIG) welding process without any interlayers. The main challenge is to get the symmetric weld bead profile. Flux coating is optimized in terms of flux composition, coating density, and coating pattern to get the full penetration with symmetric appearance. The current work discusses the possible cause and their solution of asymmetricity during dissimilar welding. Differential flux coating density is found to be very effective in controlling the arc column shape, fluid flow, and consequently the bead geometry. High coating density is used in the P91 side compared to 316L side. Symmetric weld profile with full penetration is achieved by applying multicomponent flux (33–38% TiO2, 38–43% SiO2, 13–17% NiO, and 8–10% CuO) during A‐TIG welding.

Thermal Stability and Heat Transfer of Polyurethanes for Joints Applications of Wooden Structures.

Wood characterized by desired mechanical properties and wood joining material is essential for creating wooden structures. The polymer adhesives are suitable for such applications due to the possibility of energy dissipation from stresses generated by wooden structures and the elimination of thermal bridging, which are common problems in metal joining materials. This research focuses on the thermophysical properties of the laboratory-prepared flexible and rigid polyurethanes to select an appropriate polymer adhesive. Our results showed that the highest thermal stability was in the case of the new PSTF-S adhesive, which reached 230 °C, but the lowest mass loss in the air environment was around 54% for the PS material. The mean thermal expansion coefficient for F&R PU adhesives was 124-164∙10-6 K-1. The thermal diffusivity of examined adhesives varied between 0.100 and 0.180 mm2s-1. The thermal conductivity, depending on the type of polyurethane, was in the 0.13-0.29 W∙m-1∙K-1 range. The relative decrease in thermal diffusivity after heating the adhesives to 150 °C was from 2% for materials with the lowest diffusivity to 23% for the PU with the highest value of heat transfer. It was found that such data can be used to simulate wooden construction joints in future research.

Element-based finite volume method applied to autogenous bead-on-plate GTAW process using the enthalpy energy equation

The welding process is the most used technique for metal joining. Understanding the temperature variation along the welded part during the process can prevent the appearance of failures. The experimental investigation process is quite time-consuming and costly. Therefore, numerical simulation processes based on the finite difference method, finite element method, finite volume method, or meshless Element-Free Galerkin (EFG) methods are important tools to optimize the welding process. The main goal of the present study is to show the feasibility of the Element-based Finite-Volume Method (EbFVM) approach for actual engineering applications. To solve the unsteady 2D and 3D thermal energy equation using enthalpy as an independent variable, an in-house Fortran code has been developed based on the EbFVM approach in conjunction with unstructured and structured meshes. The numerical simulations, with four types of different heat sources, were performed for applications of real welding processes with variations in density and enthalpy as a function of temperature. The results are presented in terms of thermal cycles and temperature fields. Furthermore, the developed code was confronted against experimental works from the literature, simulated and lab-controlled experiments with AISI 409 ferritic workpieces, and exact analytical solutions with thermocouples fixed in different positions. In general, the numerical results from the current investigation are in close agreement with the results from the literature and the experimental results performed by the authors. The numerical results also highlighted the differences between the 2D and 3D models for thermal cycles near the bead weld.

Tensile test and hardness test on FCAW-GS welding results of AB/EH36Z35 material in 3G downhill position

Welding is a crucial aspect of the modern construction industry as it allows for efficient and reliable joining of metals. The purpose of this research is to evaluate the FCAW-GS welding process on AB/EH36Z35 material in the 3G downhill position. Additionally, the study aims to analyze the tensile and hardness test results of the welding. The research utilized the FCAW-GS welding method, with tensile testing conducted by the AWS D1.1/D1.1 M:2015 standard. Hardness testing was performed using the Vickers hardness test method with a test load of 10 Kgf, following the ASTM E92:2017 standard. The results of the tensile tests demonstrate that both specimens achieved high tensile strength. Furthermore, the hardness testing indicated no significant changes in material hardness in the HAZ and Line 3 areas. Consequently, this study's findings adhere to the quality standards outlined by AWS D1.1/D1.1M:2015 and ASTM E92:2017, making them a valuable reference for industrial welding processes

Microstructural evolution and fracture behaviour of dissimilar Al/Steel lap joints by laser beam oscillating welding

ABSTRACT The hybrid metal joining of aluminium alloy and steel has become the most intensively used candidate material for energy conservation and emission reduction in the automotive industry because of the comprehensive properties of low density, high strength and good corrosion resistance. In this work, experimental investigations were conducted on the laser beam oscillation welding of galvanised steel and aluminium alloy arranged in a lap configuration. Well-formed joints were successfully obtained with the aid of beam oscillating. Zigzag structures were observed at the interfacial area of Al–Fe joints instead of blocky structures due to the oscillation-driven effect of the beam. The stirring effect of the oscillating beam can promote the migration of the solute during the laser welding process, thus inhibiting the separation of components and decreasing the vulnerability to cracking. The interface zones of the laser-welded Al–Fe joints were principally made up of the Fe2Al5, FeAl, FeAl2, FeAl3 and Fe2Al5Zn0.4 phases. The joints welded with beam oscillation exhibited a tensile load and elongation amount of 1.07 kN and 0.775 mm, respectively, representing 115.67% of the loading capacity and 119.23% of the elongation compared to laser beam-welded joints without oscillation.

Direct Joining of Metals and Injection molded Plastics via Micro-/Nano-Textures

Direct Joining of Metals and Injection molded Plastics via Micro-/Nano-Textures

Unveiling the Potential of Friction Stir Welding for Seamless Metal Joining

Friction Stir Welding (FSW) has revolutionized metal joining in manufacturing by offering robust joints without defects. This study examines FSW using specific parameters and evaluates its impact on mechanical properties and microstructure. Through rotational speed (2192 RPM), welding speed (36.3 mm/minute), tool tilt (3.4°), and concave shoulder angle (9°), FSW was applied to predetermined metal materials. Impact and Vickers tests were conducted post-welding to assess toughness, surface hardness, and microstructural changes. Results highlight the significant influence of FSW parameters on material properties, providing insights for optimizing efficiency and quality in the manufacturing industry. The study's findings contribute to addressing knowledge gaps and advancing FSW applications in industrial settings. Highlight: Precise Parameters: Control for strong joints in manufacturing. Toughness Evaluation: Assessing joint resilience under dynamic loads. Industry Optimization: Enhancing efficiency and quality in metal joining processes. Keywoard: FSW, Manufacturing, Mechanical Properties, Optimization, Impact Testing

Ultrastrong heterojunctions without bubble defect in laser joining metal to polymer via two-step strategy

A two-step joining approach was proposed to minimize or eliminate decomposition bubbles in laser joining metal to polymer. Finite element simulation was utilized to analyze the temperature distribution and incorporated the bubble shrinkage mechanism and thermal capillary effect, providing the theoretical basis for explaining the reduction in bubbles and their movement. Two experimental setups were employed: with and without laser beam offset. In experiments without offset, the bubbles after the second joining process underwent significant shrinkage, resulting in a notable reduction in volume. In offset experiments, the bubbles not only reduced in size but also exhibited movement and elimination. This was induced by the laser beam offset, which created a temperature gradient perpendicular to the joining direction, triggering thermal capillary effects that caused the bubbles to migrate towards the hotter side and eventually escape from the joint edges. Consequently, the joints obtained through double welding exhibited higher fracture stress as compared to those obtained through single welding. The theoretical analysis of the bubble reduction mechanism aligned with experimental observations, further validated by camera images.

The Effect of Friction Stir Weld (FSW) Process Parameters on Tensile Strength, Macro Structure, and Hardness in Results of AA7075 Butt Joints

Friction Stir Welding (FSW) is an innovative technique that enhances the conventional method of joining metals. Notably ecofriendly due to its energy efficiency, FSW involves minimal energy input, reduces pollution, and saves time and costs. It finds applications in diverse sectors such as automotive, aerospace, and industry. Each material requires specific process parameters, which leads to this study focusing on identifying suitable parameters for AA7075 aluminum with a 6mm thickness. Using a tool featuring a tapered cylindrical thread pin and a flat shoulder, the study aims to investigate the influence of FSW process parameters, rotation speed, and traverse speed on the mechanical strength of butt joint connections. The study's experimental design varies these parameters and evaluates the joints through tensile strength testing, hardness testing, and macrostructural analysis. Utilizing Response Surface Methodology (RSM), the data highlights the impact of rotation and traverse speed on tensile strength. Hardness test results present variations within heat zones, analyzing the effects of the mentioned variables. The findings demonstrate minimal flash and successful surface outcomes but also identify wormholes within the stir zone (SZ). Tensile strength testing reveals a definite correlation between RPM and traverse speed with joint strength. In contrast, hardness testing indicates that these parameters do not significantly affect joint hardness. Macrostructure examination suggests RPM and traverse speed have negligible effects on the heat-affected zone. In conclusion, FSW presents a sustainable and effective welding approach with implications for multiple industries, and this research provides insights into optimizing its parameters for specific aluminum materials.

EFFECT OF ELECTRODE ON JOINING TWO DISSIMILAR METALS (SS & MS

This study examines the challenges associated with joining dissimilar metals, specifically stainless steel and mild steel, and investigates the impact of electrode selection on joint quality and characteristics. Various welding processes, including shielded metal arc welding (SMAW), is explored. Experimental findings indicate that electrode choice significantly influences the formation of intermetallic compounds, fusion zone morphology, and mechanical strength of the joint. Alloying elements in electrodes are found to enhance weldability and performance by facilitating metallurgical bonding and reducing the formation of brittle phases. Furthermore, the study explores variations in welding parameters to optimize the process for desirable joint properties. By deepening our understanding of electrode roles in welding dissimilar metals, this research offers insights crucial for selecting appropriate techniques and parameters, ensuring reliable joints. These insights have broad applicability across industries such as automotive, aerospace, construction, and manufacturing, where dissimilar metal joining is common. Key Words: dissimilar metals, intermetallic compounds, Weldability, morphology, mechanical strength.

Investigation on the joining process and strength of laser circle welding between Al5052 and CFRP dissimilar materials

Laser welding is an effective approach to joining metal and composite. In the present research, laser circle welding was proposed to join the Al5052 sheet and PA6-CFRP as the first try. A process window was suggested according to the welding results and joint appearance. Single lap shear test was employed to evaluate the mechanical performance of welded joints under different welding conditions. The cross-section and fracture surface were subjected to multi-scale characterizations to subdivide the joining zone and understand the joining process. The result showed that 10 sets in 18 groups of welding parameters can achieve successful bonding. The welding results can be classified into four categories: non-connected, aging-failing, effective-joining and burn-through. The joining zone of laser circle welding was divided into three subregions. The adhesive zone (AZ) presented an interfacial fracture while the local failing passed through plastics basement in cohesive (CZ). The overheating of CFRP generated decomposed zone (DZ). The signal peak of O-C=O bond disappeared in the entire joining zone on CFRP sheet and the intensity of carbide was significant in DZ. The laser circle welded joint presented brittle and ductile fracture modes, which were related to the joining zone component. The joining strength can reach about 656 ± 22 N, 2135 ± 331 N and 3223 ± 257 N under one-circle, double-circle and three-circle scanning, respectively. Increased scanning numbers can decrease the required laser power and improve joining strength by extending heating time, while it also increased the risk of burn-through.

The “Third Body” Approach to Joining of Metals by Simple Shear under Pressure

A continuum mechanics approach to cold welding (CW) of metals under shear is considered. The main idea is to treat a weld joint as an extra material—a “third body” in its own right. Its properties stem from plastic co‐deformation of the two contacting alloys. The mechanical characteristics of the weld joint, i.e., its strength and plasticity in the complex stress state, are determined by the deformation history of the “third body.” The proposed approach enables a unified description of the CW process itself, as well as the subsequent variation of shape of the composite material with the weld joint.