Joint Interface Research Articles

Optimizing Interfaces in Laser-Brazed Ceramic-Stainless Steel Joints for Hydrothermal Sensors through Finite-Element Modeling

The development of reliable joining techniques for ceramics and metals is crucial for energy applications, such as fuel cells, nuclear reactors, and high-temperature sensors, most especially for the sealing of hydrothermal sensors to study multiphase flows. However, during one-step active laser brazing it is a serious problem that a high thermal stress concentration can occur at the joint interfaces or on the ceramic side of the joint due to mismatches between the CTEs (coefficients of thermal expansion) and/or elastic constants. The uncontrolled thermal residual stress can lead to cracks and defects in the brazement. In the present work, an elastoplastic finite element method/numerical model was formulated to study the thermal residual stresses developed in the brazement between ceramics and austenitic stainless steel during cooling in active laser brazing. Calculations and comparison experiments were conducted to validate the simulated stress distribution in un-patterned ceramics. Stress analyses were conducted for planar and cylindrical specimen geometries (lab joints) relevant for miniaturized energy sensors. Laser interface patterning was employed to create micro-scale features on ceramic interfaces that reduce thermal stress concentrations. The optimization of the interface designing parameters including hatch size, structure width, pattern depth and metal/ceramic thickness ratio was performed using the Taguchi method with orthogonal arrays. The study suggests that laser interface structuring can modify thermal residual stresses in ceramic-to-metal brazements, thereby increasing the reliability of active brazing joints.

Solder joint shape optimization and thermal-mechanical reliability improvement for microwave RF coaxial connectors

Coaxial connectors are widely used in microwave RF components in wireless communication, aerospace, and other fields. However, the poor interconnection reliability between their inner conductors and circuit boards has been a key factor restricting their development. Thermal cycling and high temperature are the most common working loads for high-frequency devices and the failure generally takes place at the solder joint interface. Therefore this study investigated the solder joints thermal-mechanical reliability of coaxial connectors through a combination of numerical simulation and reliability experiments. Three innovative initial models were used to solve the shape simulation problem of solder joint in planar-curved composite structures. The optimal solder joint shape and structural parameters were obtained through finite element simulation, and the impact mechanism of different parameters on solder joint reliability was explained. After optimization, the maximum stress of the solder joint decreased by 44 % with thermal cycling, while the average stress decreased by 55 %. The reliability tests effectively verified the accuracy of the simulation. In addition, the 150 °C aging tests clarified the kinetics of the growth and evolution of intermetallic compounds in this solder joint structure. The results contribute to the advancement of coaxial connectors solder joints reliability and support the development of more robust and durable interconnects for microwave devices and digital communication systems.

A study on the formation and failure mechanisms of CF/PPS-metal induction welding joints strengthened by micro-pins

This study proposed a novel hybrid joining technique that combines through-thickness reinforcement (TTR) and induction welding methods to address the challenges of composite-metal joining. The effects of geometrical parameters of micro-pins on the formation and bearing performance of hybrid joints were investigated by combing the experimental and numerical simulation approaches. Two simulation models which included the induction heating transfer and joint tensile failure process were established by COMSOL Multiphysics and Abaqus/Explicit. Subsequently, digital image correlation (DIC) was used to monitor the deformation process of different types of joints under tensile load, and a scanning electron microscope (SEM) was used to observe the welding interface of failed joints. By comparing the experimental and simulation results, it is found that adding pins can significantly improve the mechanical performance of welded joints, with maximum increases of 159% and 1758% in ultimate strength and energy absorption respectively compared to welded joints without interlock structures. This technique presents a potential solution for achieving high-quality metal-composite welded structures.

Improving interface bonding strength of laser-welded steel/CFRTP hybrid joint via bilayer silane film

The γ-aminopropyltrimethoxysilane (γ-APS) and γ-(2,3-epoxypropoxy) propyltrimethoxysilane (γ-GPS) single or bilayer silane film was produced to improve the tensile property of laser-welded 304 stainless steel/CFRTP joint in this work. The bonding mechanism at joint interface was investigated through experiments as well as density functional theory (DFT) calculation. Si-O-Fe covalent bonds were formed between steel and different silane films. Hydrogen bonds were induced at the interfaces of silane coating/polymer sides. The binding energy calculation results suggested that the binding between γ-APS silane coupling agent and steel was more stable than that of γ-GPS and steel. The binding energy of −3.37 eV between amino group in γ-APS and carbonyl group in CFRTP was greater than the binding energy of −4.84 eV between epoxy group in γ-GPS and amide group in CFRTP, which indicated stronger interaction was obtained between γ-GPS and polymer compared to the interaction between γ-APS and polymer. The bilayer silane coating could combine the dominant functional groups of silane monolayer film to obtain stable bonding on both metal side and CFRTP side. Moreover, compared with silane single film, longer silane oligomer molecular chain length was provided by bilayer silane film, resulting in more entanglement sites between silane film and CFRTP and the increased joint mechanical property. The steel/CFRTP hybrid joint reached maximum tensile shear strength of 17.2 MPa, which was further increased by 115.0% and 79.2% than that obtained by γ-APS and γ-GPS silane single coating, respectively.

Effect of defocusing distance on interfacial reaction and mechanical properties of dissimilar laser Al/steel joints with a porous high entropy alloy coating

Aluminum alloy and low carbon steel were successfully laser weld-brazed when using a porous high entropy alloy (HEA) transient layer. It is shown that the joint wettability increased with the decreasing defocusing distance and the best wettability was obtained at 0 mm defocusing distance with the contact angle of 59.8° and wetting length of 5.57 mm. A fine and dense layer of τ5-(Fe,Co,Cr,Ni)1.8Al7.2Si phase was observed wrapping around the HEA spheres, and its thickness changed in a pronounced way with the defocusing distance, where a maximum thickness of 3.20 μm was obtained at 0 mm. A non-coherent interface and a composite-like structure was formed between the τ5 phase and the HEA spheres. However, the τ5 phase, consisting of a large number of nano-grains, aided in realizing the residual stresses at the joint interface through dislocation slip, leading to an enhanced interfacial bonding and joints failure near the fusion zone. An outstanding fracture load and displacement were achieved, with 333.9 N/mm and 4.07 mm respectively, at the optimized condition of 0 mm defocusing distance. And the mechanism of diffusion and metallurgical evolution was also revealed by thermodynamic calculations and diffusion kinetic analysis.

Influence of protein migration on the fretting-corrosion behavior of 316 L stainless steel with artificial crevices

Fretting-crevice-corrosion at the modular interface of artificial joints can cause failure of the joint replacement. In this study, long-term fretting crevice corrosion tests of 316 L stainless steel were carried out at the center of an artificial crevice in a saline solution with and without proteins. The results showed that fretting initiated significant crevice corrosion without proteins and corrosion of large areas was observed in the non-contact area inside the crevice. In the presence of proteins, proteins can migrate into the crevice and block the crevice mouth. The enriched proteins had a lubricating effect and inhibited the occurrence of crevice corrosion.

Bicontinuous microstructure formation of immiscible phases by the liquid metal replacement method and its application to Ti/Mg dissimilar joining

We designed a new microstructure control method (liquid metal replacement method) that creates entirely new composites using the original microstructure as a template. This method selectively replaces a specific phase from a composite with another phase based on differences in atomic interactions. We applied this method to the dissimilar material joining of immiscible titanium and magnesium. After diffusion bonding one side of an interlayer consisting of α-Ti / α-Sc phases to Ti, we butted the opposite side with Mg and reheated. At this interface, selective interdiffusion of Mg and Sc results in the replacement of only the α-Sc phase by the α-Mg phase, forming a new α-Ti / α-Mg bicontinuous microstructure using the α-Ti / α-Sc monotectoid microstructure as a template. The Sc that diffused to the Mg side formed a reaction layer where the MgSc (B2) and (Mg, Sc) solid solution coexisted. These novel composite structures and reaction layers strengthened the joint area. As a result, we suppressed fracture at the joint interface, causing fracture at Mg and achieving a maximum joint strength of 116 MPa.

Microstructure and Mechanical Properties of Electrically Assisted Brazing Joints of Dissimilar Aluminum and Steel Alloys

The microstructure and mechanical properties of electrically assisted brazing (EA-brazing) joints of aluminum alloy 6061-t6 (AA6061-t6) and S45C steel are experimentally investigated. During the EA-brazing process, an electric current is directly applied to the cylindrical specimen assembly (S45C and AA6061-t6) and fillers of 88% Al and 12% Si (in the middle of the specimen assembly). The temperature of the specimen assembly rises rapidly to the melting point of the filler and remains nearly constant for a period of time using a pulsed electric current. Two types of EA-brazing joints are fabricated, namely Joint-0s (no temperature holding time) and Joint-12s (12 s temperature holding time). The characteristics of the intermetallic compounds (IMCs) formed at the EA-brazing joint interface are analyzed using scanning electron microscopy and energy dispersive spectrometer. Compared to Joint-0s, the Fe-rich IMCs (FeAl) are observed at the interface of Joint-12s due to the 12 s temperature holding time. In addition, the microstructural analysis shows that the thickness of the diffusion layer increases with increasing temperature holding time. The mechanical properties of the EA-brazing joints are evaluated using bending tests. The results of the mechanical test show that the strength of Joint-12s is higher than that of Joint-0s.

Influence of zinc (Zn) powder on the microhardness characteristic and microstructure properties of stainless steel SS304 hybrid joint using low power microwave heating

AbstractMicrowave hybrid heating (MHH) process is a unique and novel approach of joint materials. Several lightweight materials (medium and high melting point) such as nickel, copper and aluminum have been successfully joined in the past research. However, small dimensions and low melting point of light weight materials such as zinc (Zn) metal or zinc (Zn) powder were always being a challenging mere for creating bond via any joining techniques. The sheets of stainless steel SS304 (17 mm×7.9 mm×0.2 mm) have been fabricated and joined at lap joint by using novel Microwave hybrid heating technique with mini heat chamber of 2.45 GHz of frequency and 200 W–360 W of microwave power, using pure zinc powder (99.9 %) as an interface material. Epoxy rate and exposure time have been varied from 10 % to 20 % and 2 min to 4 min, respectively. A developed heat chamber has been set in domestic microwave oven properly as proposed. To evaluate the microstructure correlation and microhardness at joint interface, the field emission scanning electron microscopy (FESEM – EDS), x‐ray diffraction (XRD) and Vickers hardness were used. For the experimental studies, it had found an excellent bonding was produced at interface layer between the upper and lower sections with good penetration rate of 360 W of microwave power, 4 min of exposure time and 20 % of epoxy rate as the 183.1 HV 0.05 of excellent microhardness and the intermetallic phase of iron‐zinc (FeZn11), nickel‐zinc (NiZn) and nickel‐zinc (NiZn3) were observed at interface layer.

Experimental and Numerical Investigation on Flexural Strengthening of Precast Concrete Corbel Connections with Fiber-Reinforced Plastic Sheet

This paper presents the results of experimental and numerical investigations aimed at enhancing the flexural capacity of Precast Concrete Corbel Beam–Column Connections (PC-CBCCs) using Fiber-Reinforced Plastic (FRP) sheets. The experimental study primarily focused on assessing the flexural capacity of pinned PC-CBCCs reinforced with FRP layers, comparing them to a moment-resisting connection. A series of half-scale specimens, including three PC-CBCCs with varying FRP configurations, were tested alongside one in situ concrete fixed connection. The first specimen (PC-1) utilized L-shaped and full-wrap FRPs, whereas PC-2 and PC-3 employed both U-shaped and full-wrap layers. The objective is to quantify the ultimate flexural capacity of PC-CBCCs reinforced by FRP sheets. In PC-3, the external anchorage is introduced to assess its influence on delaying the FRP layer debonding under lateral loading. The effects of the FRP layer thickness, locations, and potential debonding are examined under unidirectional static tests while applying a constant axial compressive load to the columns and subjecting the beams to lateral loads until fracture. The test results illustrate that strengthening the corbel connection with L-shaped FRP or spiral U-shaped FRP sheets without mechanical anchorage cannot result in a significant bending capacity due to debonding. However, with the incorporation of mechanical anchors, the connection manages to enhance the moment capacity to 81% of a fixed connection’s flexural capacity. Additionally, a finite element model of the PC-CBCCs and a fixed joint is developed to simulate nonlinear static analyses of the connections using ANSYS 19.2 software. The simulation model is precise in predicting the initial stiffness and ultimate capacity of the beam–column joints, as verified by the experimental results. A comprehensive comparison is conducted to determine their responses by employing various FRP configurations and properties. Moreover, design parameters such as bond length and thickness of the FRP sheets, along with appropriate mechanical anchorage, are identified as effective in preventing debonding, and delamination. However, wrapping the beam far away from the joint interface has a minimal impact on the failure mode, stress reduction, and load-bearing capacity.

In vitro drug release and cartilage interface lubrication properties of biomimetic polymers

Osteoarthritis is a degenerative disease that is widely found in the elderly population, with a trend towards a younger age group in recent years. In the early stages of arthritis, patients are treated with hyaluronic acid injections and anti-inflammatory drugs. However, it has been found that hyaluronic acid can only play a supportive role and does not have a lubricating effect, and due to the absence of blood vessels, nerves, and lymphatic vessels in the articular cartilage, the oral anti-inflammatory drugs cannot reach the interface of the inflammatory joints adequately, and the drug utilisation rate is low. Herein, we designed and prepared a brush-like bionic lubricant for joint lubrication and drug loading. The poly(2-methyl-2-oxazoline) branched chain was grafted onto the hyaluronic acid main chain by ring-opening polymerisation and graft polymerisation to form a brush-like bionic lubricin containing multiple hydrophilic groups, which was self-assembled to encapsulate the drug by using its multi-branched special structure for drug loading. The friction behaviour tests on the articular cartilage surface showed that the prepared bionic lubricin has excellent lubrication effect, with a minimum friction coefficient of 0.036 close to the lubrication effect of natural synovial fluid, which is mainly due to the hydrophilic groups on its molecular chain that can adsorb the water molecules and form a hydration layer at the cartilage interface, which plays the role of hydration lubrication. In addition, in vitro drug release studies showed that the synthesised drug-loading biomimetic lubricin had a certain drug release capacity, and the maximum drug release rate could reach 77.8 % at 72 h. The synthesis of this bionic lubricant with dual functions of lubrication and drug release provides a new idea for the treatment of osteoarthritis.

Microstructure and Mechanical Properties of Ti6Al4V to Al2O3 Brazed Joints Using Ti-Ag/Cu-Ti Thin Films

The processing and characterizing of bonding Ti6Al4V to Al2O3 brazed joints using interlayer thin films was investigated. The brazing was conducted in a tubular furnace with an argon flux at 980 °C for 30 min. The brazing fillers consisted of different combinations of thin Ag/Cu and Ti films with variable thicknesses. The joint interface analysis involved using digital microscopy (DM) and optical microscopy (OM). Microstructural characterization and chemical composition were performed via scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). Mechanical properties were assessed through microhardness and shear strength tests. Brazing successfully produced interfaces with a combination of titanium films and Ag/Cu as brazing filler. The results revealed that the interface mainly comprises Ti2Cu, TiCu2Al, α-Ti, and Ti2(Cu,Ag). Some segregation of (Ag) was observed at the interfaces, but a decrease in its amount was observed when compared to joints produced using Ag/Cu fillers. The thickness of the titanium film in the brazing filler strongly influenced the integrity of the joints. The amount of (Ag) at the interface diminished as the Ti film’s thickness decreased, leading to an improvement in the mechanical properties of the joints. Using a combination of Ag/Cu and Ti thin films revealed a potential approach to reduce the segregation of soft phases at interfaces, promoting a significant improvement in joining metal to ceramic materials.

Microwave joining of copper pipes using selective microwave hybrid heating process: Simulation and experimental study

High thermal conductivity of copper poses serious challenges in its joining in conventional welding techniques leading to development of alternate welding techniques. Microwave welding is one such newly developed joining technique that use selective microwave hybrid heating (SMHH). The joining of the copper pipes using SMHH has not been explored in existing literature. The present paper attempts the microwave joining of copper pipes using SMHH. The exposure time required for joining copper pipes using SMHH was predicted by COMSOL Multiphysics software. The joining was attempted at the predicted exposure time using a novel cavity design inside a conventional microwave oven. The copper pipes have been successfully joined at temperature and exposure period of 1080ºC and 720 s respectively and was in good agreement with the predicted values i.e., 708 s. Scanning electron microscopy (SEM) revealed good metallurgical bonding between the base metal and joint interface. The presence of columnar grains has been observed at heat affected zone (HAZ) using electron back scattered diffraction (EBSD). EBSD analysis revealed randomly arranged grains with mixed modes of planes inside the base metal. The occurrence of high angle grains (HAGs) along with high dislocation density in base metal resulted in the improvement in the mechanical properties as revealed in grain average misorientation (GAM) maps. The maximum value of microhardness has been observed at the joint region (105 ± 7 Hv) followed by base metal and HAZ i.e. (97 ± 5 Hv) and (89 ± 8 Hv) respectively owing to the existence of fine grain of copper (µm) and carbide formation.

Lap shear properties of CF/PEKK composites through nanoparticle-enhanced adhesive joints

This study investigates the effects of incorporating halloysite nanotubes (HNTs) into polyetherimide (PEI) adhesive for carbon fiber/polyetherketoneketone (CF/PEKK) composite joints. The CF/PEKK substrate is fabricated through an oven consolidation process, while PEI adhesive films with varying HNTs loadings (0.5, 1 and 3[Formula: see text]wt.%) are prepared using solvent casting with [Formula: see text]-butyrolactone. Homogeneous dispersion of HNTs in PEI is achieved through magnetic stirring and IR heating. The resulting film is hot pressed to form a 100[Formula: see text][Formula: see text]m thick film, and adhesive lap shear joint specimens are manufactured through oven consolidation. Morphology and dispersion of HNTs in PEI are analyzed using SEM and EDS, revealing favorable dispersion at 0.5[Formula: see text]wt.% HNTs and aggregation at higher loadings. Differential scanning calorimetry (DSC) is employed to study the glass transition temperature (Tg) of PEI, showing decreased Tg for solvent-cast PEI and increased Tg with HNTs incorporation. This increase is attributed to the constrained mobility of polymer chains due to HNTs’ influence. Lap shear strength (LSS) is evaluated, demonstrating enhancement with HNTs incorporation: 0.5[Formula: see text]wt.% HNTs (+12.5%) > 1[Formula: see text]wt.% HNTs (+8.33%) > Pure PEI > 3[Formula: see text]wt.% HNTs (−12.5%). The study attributes this enhancement to HNTs’ reinforcement and chemical interactions with PEKK. Aggregation tendencies at 3[Formula: see text]wt.% HNTs lead to decreased LSS. SEM-EDS analysis of fractured specimens indicates a multifaceted bonding joint interface involving PEKK, PEI and HNTs. CF/PEKK composites show adhesive, cohesive and adherend failure modes, with adherend failure being dominant. Notably, fabric-like textures and plastic deformations in PEI with 0.5[Formula: see text]wt.% HNTs contribute to enhanced LSS, while higher HNTs content leads to cohesive failure due to aggregation. This study provides insights into optimizing composite adhesive systems by harnessing nanotube reinforcement and controlling dispersion, thereby influencing interfacial strength.

Effect of co on the morphology and mechanical properties of the Sn-3.0Ag-0.5Cu/Sn-58Bi composite solder joints on ENEPIG surface

Microelectronic devices have demonstrated advanced capabilities, including multifunctionality and high input-output density, rendering them widely used in significant fields such as big data, data centers, and supercomputing. The reliability of microelectronics packages is contingent on the integrity of welded joints under diverse operating conditions for these applications. This research aims to examine the effects of 0.5 wt% Co element on the microstructure and properties of Sn-3.0Ag-0.5Cu/Sn-58Bi composite solder joints fabricated on the ENEPIG pads. The solder joints were exposed to a peak temperature of 220 °C and maintained at this level for different periods of time. The research included conducting a comparative examination on samples with and without additional Co to investigate the influence of Co inside solder joints on their microstructure and mechanical properties. The results show that the IMC changed from needle rod (Cu, Ni, Pd)6Sn5 to granular (Cu, Ni, Co, Pd)6Sn5 with the increase of holding time. The IMC at the solder joint interface added by Co changes from (Cu, Ni, Co, Pd)6Sn5 to (Ni, Cu, Co, Pd)3Sn4. The added Co element mainly exists in the form of a solid solution inside the solder joint, resulting in enhanced hardness of the Sn and Bi phases in the solder joint and a reduction in modulus.

Joint interface optimization of all-CFRTP composite honeycomb prepared by ultrasonic multi-spot welding

An all carbon fiber reinforced polyetheretherketone (CF/PEEK) composite honeycomb is prepared by the multi-spot ultrasonic welding in this work. The interfacial responses and flat compression failure behaviors of the honeycomb are firstly analyzed. It is found that ultrasonic welding has both positive and negative effects on honeycomb performance. High-frequency vibration results in fiber waviness, which is beneficial to elevating both the bending resistance of the joints and the compression strength of the honeycomb. However, melted EDs also lead to resin-rich areas at the interface. Based on the findings, the multiwall carbon nanotubes/PEEK (MWCNTs/PEEK) energy directors are developed, providing new insights on optimizing the properties of the interface. The experimental results indicate that the interfacial node tensile strength is enhanced by 400 % (1267 kPa) with the MWCNTs content increasing to 7.5 wt%, and the optimized CF/PEEK honeycomb shows more superior specific energy absorption and specific compressive strength than those of the commercial light-weight honeycombs. Moreover, the joint failure behaviors are investigated thoroughly. The addition of MWCNTs is found to induce fiber bridging between the cell walls and facilitate stress transfer through the joint interface. The optimized ultrasonic welding method provides a new opportunity for efficient and volume manufacturing of carbon fiber reinforced composite honeycombs without dimension limitation and large mold costs.

Development of a Diffusion Bonding Route for Joining Oxide-Dispersion-Strengthened (ODS) Steels for Nuclear Applications

Oxide-dispersion-strengthened (ODS) steels are candidate materials for components in current and future nuclear power plants. One of the issues with using ODS steels is the difficulty of joining them without loss of mechanical performance. In this study, austenitic ODS 316L stainless steel was diffusion-bonded to Inconel 718 superalloy. Having optimized the bonding conditions, a number of samples were made at 1200 °C with a bonding time of 1 hour and pressure of 10 MPa. Preliminary mechanical and microstructural analyses indicated the formation of a sound joint interface, despite slight grain growth in the ODS 316L. A post-bonding thermo-mechanical treatment (TMT) was conducted to refine and restore the microstructure of the ODS 316L. Comparative TEM investigations of the parent ODS alloy and the bonded samples (with and without TMT) along with statistical analyses showed that the Y–Ti–O oxide size distribution remains unaffected by the bonding and complementary TMT cycles, indicating stability of such particles even at very high temperatures and suitability of the devised route for joining the ODS 316L steel.

Preliminary study on effect of inertia and continuous friction welding on mechanical properties of SS 316-Zn alloys friction welded joint

The effect of inertial friction welding and continuous drive friction welding in joining SS 316 with Zn alloy is discussed in this article. Scanning electron microscopy was utilized to investigate the microstructure of the welding interaction. Energy-dispersive spectroscopy was utilized to identify the chemical composition of the element distribution at the interface. The findings reveal that a continuous drive friction welding process may produce SS 316 welded joints with Zn alloy. With a friction time of 35 s, the joint's tensile strength may reach 60 MPa. During the tensile test, all friction-welded samples failed at the interface. The fracture surface shows an almost flat surface and is not fibrous or brittle. Meanwhile, a new reaction layer from the intermetallic compound layer is not formed at the joint interface. The decrease in hardness in Zn alloys is due to the thermal softening effect caused by continuous heat from friction.

Study on interfacial morphologies of AA1060 and SS321 magnetic pulse welded joints

In this study, the application of magnetic pulse welding was employed for the production of tubular joints using 1060 aluminium and 321 stainless steel. Two crucial process parameters, the charging voltage, and the gap between the outer and inner tubes, were subjected to mechanical property tests and morphology analysis. The joints that exhibited favourable mechanical properties were obtained with a gap size of 1.25 mm and a charging voltage exceeding 3.5 kV. The presence of intermetallic compounds at the joint interface indicates the occurrence of fusion in the transition zone. The quantity of molten metal increased with an increase in the charging voltage. The aluminium content in the intermetallic compounds within the transition zone decreased as one moved from the 1060 aluminium side towards the 321 stainless steel side. The gap distance plays an important role in determining the efficiency of energy transformation at the joint interface during magnetic pulse welding (MPW). A smaller gap distance resulted in a substantial amount of energy being transformed into plastic deformation in the transition zone. Conversely, a greater gap distance led to a significant amount of energy from the electrical charging voltage being converted into thermal energy. The MPW joint consisted of bonding, mechanical interlock, and non-bonding regions. The mechanical properties of the joint were influenced by the composition of the intermetallic compound. Taking into account the impact of morphologies and elastic modulus of the transition zone, an increase in the melting of stainless steel during the welding process was found to be advantageous for the MPW of 1060 aluminium to 321 stainless steel.

Microstructure and mechanical properties of ultrasonic spot welding of AA7075-T6 and A380 casting aluminum alloy

Ultrasonic spot welding (USW) was employed to join AA7075-T6 and casting Al alloy A380. Under a constant welding power, the influence of the welding time duration (from 1 s to 3 s) on peak temperature, microstructure, hardness, and mechanical strength of the joints were studied. It was found that the peak temperature increased with welding time. A sound solid-state metallurgical bonding was obtained at the joint interface. The cracks occurred at the edge of the joints were eventually eliminated as the welding time increased. A layer of refined grains formed in A380 adjacent to the bonding line. Hardness reduction occurred in AA7075 at the joint interface and the degree of hardness reduction and the volume increased with the peak temperature. By increasing welding time, lap shear tensile tests show that the peak load increased from 5.3 kN to 6.55 kN. The corresponding interfacial shear strength ranged from 96.29 MPa to 99.72 MPa, lower than the shear strength of both base materials (331 MPa for AA7075 and 185 MPa for A380). All joint samples exhibited interfacial fracture after lap shear tensile testing, with a thin layer of A380 remnant attached to AA7075 at the center of the fractured surface.