Joint Quality Research Articles

A new method of magnetic pulse welding of dissimilar metal plates using a uniform pressure electromagnetic actuator based on pre-deformation

The magnetic pulse welding method using a uniform pressure electromagnetic actuator can effectively weld dissimilar metal plates. However, the existing uniform pressure welding method leads to serious thinning of the plate at the chamfer, lack of welding at the center, and bulging of the welded sample, which seriously affects the quality of the welded joint. To solve these problems and improve the quality of welded joints, a new uniform pressure welding method of dissimilar metal plates based on pre-deformation was developed in this work. In this study, using the welding of an AA1060 aluminum plate and an SS304 steel plate with a thickness of 1 mm as an example, it was confirmed through numerical simulation and experimental research that the pre-deformation of the flyer plate controlled the impact angle of the central area of the plate, and it effectively suppressed central non-welding and serious bulge issues. Further, the welding method also reduced the height of the cushion blocks on both sides, thus mitigating aluminum plate thinning at the chamfer, ultimately improving the tensile strength of the joint. Additionally, a microscopic observation showed that the welding interface formed a wavy composite interface, and the connection strength was good. This welding method can also be extended to welding other dissimilar metal plates.

Exploring the impact of wire core diameter on microstructure and joint properties in ultrasonic wire harness welding

The present study investigates ultrasonic metal welding to manufacture 10 mm2 copper (Cu) wire joints with different core diameters. The primary purpose of this study is to explore the influence of wire core diameter on the performance of ultrasonic welded joints. Wire core diameter is positively correlated with the peeling resistance of the joint. Superior mechanical properties of the joint are achieved with an increased diameter of the wire core. The peeling strength of the welded joint of two wires with a wire core diameter of 0.25 mm reaches 306.8 N. Examining the welding temperature and assessing the joint's porosity reveals a significant impact of temperature on porosity. However, relying solely on porosity as a criterion for judging the overall forming quality of joints may be insufficient. Scanning electron microscope and energy-dispersive X-ray elemental analysis revealed that certain wires underwent plastic deformation at elevated temperatures without attaining atomic bonding. Additionally, the welded joint exhibits a compact structure externally and a more relaxed structure internally. The upper side of the joint in contact with the briquette and the lower side in contact with the welding head exhibit minimal gaps, while numerous gaps are evident in the middle of the joint. Furthermore, upon examining the fracture morphology, two distinct failure modes are identified at the joint surface of the conductor. The first involves the fracture of the wire core with a completely separated joint surface, resulting in poor mechanical properties of the joint. The second mode entails the ductile fracture of the wire core at the joint surface, indicating good mechanical properties of the joint.

Study on the failure mechanism and mechanical properties of multi-layer hole-drilled self-piercing riveted three-layer steel/aluminum hybrid joints

To promote the application of the three-layer steel/aluminum hybrid sheet in the lightweight vehicle body, the multi-layer hole-drilled self-piercing riveting (MH-SPR) process is proposed. This paper aims to investigate the failure mechanism and mechanical properties of three-layer MH-SPR joints and explore the effects of overlap type and pre-drilled layer on forming quality, mechanical properties, failure modes, and fracture characteristics of the three-layer MH-SPR joint in detail. Three overlap types (e.g., type A, type B, and type C) and three pre-drilled layers (e.g., J0, J1, and J2) are designed for the experimental study and the shear experiments and full-field strain measurements are carried out. The results show that the pre-drilled layer can improve SPR joinability and reduce the peak force and energy consumption during the riveting process. Overlap types A and C can increase the peak force of the joint and type C can simultaneously enhance the peak force and energy absorption of the joint. The increase in the pre-drilled layer can increase the peak force and energy absorption of the joint. The overlap types and pre-drilled layers change the failure modes of the joints, which include five types of failure modes: middle sheet tearing, top sheet tearing, rivet fracture, interlock failure, and mixed failure. Full-field strain analysis shows that the overlap type improves the mechanical properties of the joints by altering the deformation mode of the steel sheet. This work provides a theoretical basis for expanding the industrial practice of the MH-SPR process and improving the joined quality of the three-layer joint.

Atmospheric-pressure plasma jet texturing of C/C composites for improved joint strength

This study explores the use of air-fed atmospheric pressure plasma jets (APPJs) as a pre-joining treatment for 3D carbon fiber-reinforced carbon matrix composites (C/C) with the aim of both creating a textured surface that resembles a brush structure and improving the joint strength.The effects of various treatment time lengths on the mass loss, etching depth, and surface texture were investigated using SEM and confocal microscopy. An optimal process time of 30 s was selected, while keeping the other process parameters fixed (air flow of 1750 l/h and nozzle-sample distance of 5 mm). Wetting tests were conducted at 1000 °C, on both untreated and pre-treated C/C surfaces by means of liquid TiCuNi brazing alloy, and low contact angles of about 20° were measured. C/C–TiCuNi–C/C and C/C–TiCuNi–Cu joints were then produced, and their interfacial reactivity was evaluated. The apparent shear strength measured for the APPJ-treated C/C–Cu joints was 140 % higher than the value recorded for the untreated joints, thus confirming the effectiveness of the treatment.Even though a further investigation is needed in which an optimization of the process parameters should be included, this preliminary study has revealed the viability of APPJ as a promising technique to enhance the bonding of C/C composites in dissimilar assemblies and to improve the joint quality.

Intermetallic Compounds in Solder Alloys: Common Misconceptions

Intermetallic compounds (IMC) or intermediate phases are formed between two or more metallic elements in many metal alloy systems. During soldering, an IMC is formed at the soldered interface as the molten solder reacts with an element in the substrate. IMCs also can form within the bulk solder as the joint solidifies. IMCs have critical roles in the solder joint quality and reliability. Unlike most metal alloys, an intermetallic compound typically has a fixed stoichiometry and is in variance with the conventional phases or constituents in the metal system (e.g., alpha and beta). IMCs have a different crystal structure than any of its constituents and some but never all the characteristics and properties of its constituents. Ductility is an important solder joint property, and the low intrinsic ductility of IMCs is associated with brittle behavior and reliability risk in service. However, a review of published solder field failures shows little evidence that IMC properties or IMC evolution under service conditions reduce solder joint reliability. Most IMC-induced solder joint failures are found to result from incorrect material specification or uncontrolled soldering processes. This paper describes the IMCs that occur typically in eutectic, Sn63Pb37 solder and near-eutectic SAC305 or other tin-based Pb-free solder alloys, including how they impact solder joint reliability. The paper also describes the potential impact of IMCs on the solder joint reliability for the newest generation of Pb-free high-performance solder alloys.

Effects of recrystallization on interfacial microstructure evolution and shear strength of TiAl alloy joints

The effects of dynamic recrystallization (DRX) and post-bonding heat treatment (PBHT) on the interfacial microstructure evolution and mechanical properties enhancement of Ti-43Al-4Nb-1Mo-0.2B alloy joints, subjected to various bonding parameters, were thoroughly investigated through detailed microstructural characterization and shear performance tests. A strip-like DRX area was observed at the interface when bonding at 1100 °C, ≥30 MPa, for 60 min. Equiaxial- γ grains underwent discontinuous dynamic recrystallization during the bonding process, and tended to form flat grains parallel to the lamellae direction during recrystallization annealing (1000 °C/6 h) owing to the hindrance imposed by the lamellae on both sides. The orientations of lamellae on the both sides of bonding interface affects the lamellae's stress distribution and deformation behavior at the bonding interface, subsequently influencing the DRX behavior and the width of the DRX zone. Static recrystallization (SRX) during the recrystallization annealing treatment can eliminate bonding defects of joints bonding at lower pressures or temperatures. Optimal joints with fully lamellar interfacial microstructure and excellent shear properties can be obtained through single-α phase annealing treatment. Lamellae microstructure tailored through PBHT can significantly enhance the quality of joints, attributed to the homogeneity of the microstructure between the interface and matrix. The highest shear strength of 478 MPa, accounting for 82 % of the matrix strength, was obtained under the bonding parameters of 1100 °C/30 MPa/60 min-1290 °C/15 min. This work provides important DB process parameters for fabricating of complex structural parts of TiAl alloy.

Online welding status monitoring method of T-joint double-sided double arc welding based on multi-source information fusion

In modern manufacturing, double-sided double arc (DSDA) welding brings advantages in properties and efficiency for T-shaped joints. However, the double-side forming makes it difficult to detect the imperfections and ensure weld joint quality, which few studies have covered. Most existing methods deal with single-arc welding with limited sensing sources. To fill the gap, an online welding status monitoring method for DSDA welding is proposed based on the fusion of welding current, arc voltage, arc sound, and weld pool images. In pre-processing, the automatic weld pool region of interest (ROI) detection method based on the lightweight YOLO-L model and the waveform denoising algorithm are designed. In feature engineering, waveform signals are analyzed in both the time and frequency domain. A weld pool feature extractor based on a convolutional neural network (CNN) is proposed with good effectiveness and interpretability. The output feature combination is refined by Fisher-based selection and evaluation. In model building, an ensemble learning model based on three high-fit basic learners is proposed, with an accuracy of 98.538 %. The proposed model shows significant advantages over the single basic classifier and other ensemble methods. Experiments verify high precision and robustness, laying a foundation for accurate real-time monitoring of DSDA welding production.

Prediction and optimization of joint quality in laser transmission welding using serial artificial neural networks and their integration with Markov decision process

Laser transmission welding is a highly accurate method for joining plastics, but its diverse process parameters require effective modeling for optimal results. Traditional artificial neural networks (ANNs) typically establish predictive models between laser processing parameters and welding strength, neglecting the crucial role of welding morphology in feature extraction, thus diminishing accuracy. To address this, we developed a serial ANN model based on statistically evident correlations, which predicts joint morphology and strength sequentially, resulting in a 47% improvement in predictive accuracy and a mean error of just 7.13%. This two-layered approach effectively reduces the stepwise propagation of errors in ANNs, allowing the first layer to provide a refined data representation for the second layer to predict welding strength. Furthermore, finding the optimal laser parameter set is time-consuming and computationally demanding with traditional ANN-based optimization methods. To address this, we integrated the Markov decision process with the serial ANN for the first time and proposed a novel varying step strategy for the model, enabling a balance of swift convergence and avoidance of suboptimal solutions. Notably, the Markov-serial ANN model attained enhanced optimization results using only 15.5% of the computational resources required by a standard parameter interval optimization methodology. Welding experiments verified the reliability of the Markov-serial ANN, achieving a mean error of 4.54% for welding strength.

DBHF: A double fusion backbone and bidirectional feature hybrid fusion detector for high-precision inspection of avionics solder joint defects

The quality of avionics thermistor wire solder joints has a critical impact on the performance of in-orbit spacecraft. However, it is still hard to simultaneously realize a high-precision inspection of the multi-scale internal and external defects of avionics solder joints. Herein, in combination with active infrared thermography technique, an innovative DBHF detector with a double fusion backbone and a learnable weighted multi-scale bidirectional feature hybrid fusion pyramid network (BdFPN) is demonstrated based on RT-DETR framework. Specifically, the double fusion backbone framework comprises with two lightweight convolutional neural network-based backbones. Compared with conventional single backbone, the double-backbone design forms a multi-level Resnet-like structure, helping to enrich the extracted multi-dimension feature information and retain rich detail information of small-scale defects. The complex learnable weighted multi-scale BdFPN is designed for cross fusion of deep features. One or more additional multi-scale inputs are added to each node involved in feature fusion to aggregate more features from multiple scales and strengthen the interaction between low-level details and high-level semantic information, enabling the detector to make full use of multi-level feature information. Meanwhile, a learnable weight coefficient is set on each node involved in feature fusion and the importance of the input to each node is estimated by training, so that the effective information can be deeply aggregated at different levels. Our DBHF detector achieves a 92.7 % mAP@0.5 on a self-made avionics solder joint dataset with a body size of only 27.2 MB and FPS of 149, outperforming all the typical advanced real-time detectors.

Implementation of external magnetic field to improve strength of St37 steel resistance spot weld

The magnetic assist technique involves the interaction between an external magnetic field and electrical current which produces Lorentz force that influences the flow pattern of molten metal and ultimately impacts the appearance and microstructure of the weld. Many parameters may influence on this process such as welding current, time, and force as well as the working magnet distance (MD). In this study, the effects of the distance between the permanent magnet’s MD on the heat-affected zone (HAZ) and weld nugget zone (NZ) were examined through mechanical and macro- and microstructural analyses. The results demonstrated that MD has a strong influence on the magnetic flux density which determines the joint appearance, quality, and microstructure of St37 steel. Results showed that with increasing MD, HAZ increased from 8 to 22 mm2 while NZ decreased from 26 to 19 mm2, and also, the grain size increased with increasing MD and reaching 48 µm at MD was set to 9 cm. Moreover, hardness decreased at both areas through increasing MD from (120–110) HV at HAZ and from (170–150) HV at NZ. Under the action of (electromagnetic filed) EMF, weld tensile shear strength and the cross tensile strength give the highest values equal to 172 MPa and 155 MPa, respectively, when MD is set to 4.5 cm. Besides, soundness joint was obtained at MD = 4.5 cm which confirms that this is the best distance between magnets.

Design and manufacturing of Welded Vacuum Testing (WVT) tool

To ensure the quality of welded joints in the hull area, welding testing is very important and must be carried out. But unfortunately, currently the quality testing process of welded joints was still limited to penetrant tests and lime tests. The purpose of this study was to obtain a portable welding testing machine that was able to obtain fairly accurate test results on hull welding defects using a vacuum system. The research method is experimental by involving data collection through field experiments, testing is carried out with the resulting weld defect research subjects and the length of testing time on 1G and 3G position welding. The results of the study by compared tests among Welded Vacuum Testing (WVT) machines, Magnetic Particle tests (MP), and Penetrant Tests (PT). The three experiments detected leaking weld defects, spark sparks, pinholes, overlaps, and undercuts. For test results with machines made, welding defects that were successfully detected were leaks in the 1G position welding workpiece and undercut in the 3G position welding workpiece. Air bubbles at a vacuum pressure of 0.2 bar are detected, meaning that there is a defect in the welded joint. This tool can be used in bilge testing.

Application of Friction Riveting technique for the assembly of electronic components on printed circuit boards (PCB)

This study focuses on the effects of reducing the diameter of rivets used in Friction Riveting due to the need for downscaling when joining assemblies on a smaller scale. The Friction Riveting process has shown promising feasibility for a variety of material combinations and applications in the transportation industry. Recent research has explored the potential application of this technique in electronics, specifically for the assembly of printed circuit boards (PCBs), using AA-2024-T351 rivets on thin glass-fiber-reinforced epoxy substrates (FR4). The joint formation of joints produced with PCBs was investigated in terms of process temperature evolution, microstructural changes, and mechanical properties. Joints were obtained at process temperatures ranging from 285 ºC to 368 ºC. The use of 4 mm rivets resulted in extensive delamination, weak joint mechanisms, and cracking, impaired by the different coefficients of thermal expansion of the materials involved. Reducing the rivet diameter to 3 mm significantly improved joint quality. A further reduction to 2.5 mm minimized delamination but led to insufficient anchorage and cracking. Joints produced with a 3 mm rivet diameter achieved the highest ultimate tensile force of 276 N. This study sets the foundation for applying the Friction Riveting process to practical PCB assemblies, demonstrating that optimizing the process parameters to the diameter-to-thickness ratio can balance sufficient rivet anchoring, minimize delamination, and reduce cracking.

Effect of temperature on joint quality in wave soldering of Sn-9Zn-2.5Bi-1.5In lead-free solder alloy

SnZn (tin‑zinc) solder has been regarded as a promising lead-free solder material with a low melting point of 198 °C, serving as a suitable alternative to both SnPb solder due to its lack of hazardous substances and Sn-Ag-Cu solder because of the high cost associated with silver. Nonetheless, its susceptibility to oxidation hinders solderability and increases soldering defects such as bridging, insufficient fillings, and voids, limiting its use in commercial production. Devices designed with through-hole technology, in contrast to surface-mounted ones, continue to exhibit superior interconnection reliability in such applications. In this investigation on wave soldering, a newly developed lead-free solder, composed of 87% tin, 9% zinc, 2.5% bismuth, and 1.5% indium by weight, was employed under two conditions related to nitrogen content: 1) Ensuring that static oxygen content remained below 3000 ppm. 2) Maintaining soldering section oxygen content below 600 ppm at a conveyor speed of 1200 mm/min. The soldering results were examined at various temperatures of preheating and soldering. It proves that the measured peak temperature of liquid solder TpL over 230 °C makes the bridging defect rate lower than 0.30%. Additionally, setting the peak temperature of solder joint TpZ above 220 °C, along with specific preheating temperatures (105/115/135/145 °C), archives 100% vertical filling without significant voids in the solder joints. Moreover, optimizing wave soldering settings, specifically adjusting the wave soldering setting temperature Ts to 235 °C, conveyor speed vc to 1000 mm/min, resolves soldering defects associated with Sn-9Zn-2.5Bi-1.5In alloy in wave process. Relevance summary1.TpL surpasses 230 °C, the total number of bridging defects per board decreases to fewer than 6, approximately 0.30%. TpZ values of 220 °C or higher results in 100% vertical fill and no significant large voids, demonstrating optimal filling effects2.Under the conditions of TS = 235 °C and vc = 1000 mm/min yield TpL > 230 °C and TpZ > 210.9 °C, it leads to a reduction in bridging defects.3.To maintain flux efficiency and minimize internal voids, an optimal selection of preheating temperatures (105/115/135/145 °C) is demonstrated.4.An integrated nitrogen content-controlled system is utilized to eliminate oxygen from the solder pot, aiming to prevent oxidation.

Metal vapor-induced arc instability in stationary TIG-welding

The stability of the arc in arc welding processes is primarily relevant to the joint quality. However, the influencing factors which determine the arc stability are still partly unknown. Combining arc welding with laser welding enhances arc stability. The laser-induced metal vapor is often named as one stabilizing factor. But this contradicts the presumptions of arc welding researchers who mentioned the metal vapor as a destabilizing factor especially when high amounts are present in the arc. This investigation analyzes the specific influence of metal vapor on arc conductivity as one aspect of arc stability by producing metal vapor using a laser process on a separately placed substrate material. Furthermore, the arc current was varied at a constant metal vapor amount. The investigations show that the metal vapor presence increases the arc voltage by at least 20% and its fluctuation amplitude by at least 51% which was presumed to mean a decreased electrical conductivity and therefore decreased arc stability. The arc instability was lower for higher arc currents at constant metal vapor amounts. Therefore, higher arc currents increase the arc stability of welding arcs in the presence of a constant metal vapor amount.

The Effect of Channel Depth on Joint Quality in Cu/AISI 1040 Materials Joined by Mechanical Locking Method

The Effect of Channel Depth on Joint Quality in Cu/AISI 1040 Materials Joined by Mechanical Locking Method

Out-of-plane bending properties of cross laminated timber (CLT)

In Europe the structural timber building product cross laminated timber (CLT) is regulated via European Technical Assessments (ETAs), which require large and voluminous test campaigns to obtain. So far, there is no standardised CLT strength class system nor a set of harmonised properties. Such a strength class system and tabulated values could be accompanied by a set of so-called load-bearing models, analogous to the current regulations for glued laminated timber (GLT). The aims of this contribution are to comprehensively analyse the first known load-bearing model for out-of-plane bending of CLT from 2006 and to validate and benchmark this approach with possible further candidates. The aim is to initiate the establishment of a European strength class system for CLT based on its out-of-plane bending properties, for a more reliable, regulatory compliant structural building product and for enhancing its market acceptance. Therefore, a comprehensive analysis of various potential influencing parameters on out-of-plane CLT bending properties is effected by means of stochastic-numerical investigations as well as a large amount of test campaigns, the latter in the form of a retrospective study. The first approach from 2006, in particular in its adapted version, is successfully validated and confirmed as a valuable candidate for the future regulation of CLT due to its overall more accurate and more reliable strength predictions compared with the other candidates. In addition, models for the density and the modulus of elasticity parallel to the grain, as currently defined for glulam, are confirmed to be applicable also for CLT. An analysis of the variation in the properties of the base material and CLT motivates additional efforts towards grading and quality assurance in order to meet the expectations of the nominal strength class of boards and to fulfil minimum requirements for finger joint quality to better utilise the high performance of CLT and to increase its reliability.

Fatigue crack growth behavior of laser welded QP980 steel at low temperatures with water-cooling assistance

Cooling assistance holds great promise for enhancing the quality of welded joints. In this paper, the fatigue properties of laser welded quenching and partitioning 980 steel joints are improved using a water-cooling assistance process at low temperatures. This process facilitates the creation of high-quality welded joints characterized by both strength and ductility. Hardness and Charpy impact tests are conducted in conjunction with microstructure observation. Fatigue crack growth tests are performed under different stress ratios (R = 0.1, 0.3 and 0.5) at three temperatures (T = 25 °C, −40 °C and −80 °C). Results indicate that the fatigue life of welded joints increases by factors of 2.0 (at 25 °C), 2.2 (at −40 °C) and 1.5 (at −80 °C) and ductile-to-brittle transition temperature decreases with the use of water-cooling assistance at low temperatures.

Joint optimization of dynamic pricing, quality, and production quantity in the presence of online reviews: A distributionally robust optimization approach

This paper investigates the joint pricing, product quality, and production quantity decisions of a firm in a two-stage scenario, considering potential market demand uncertainty and the existence of online reviews. Two decision models are established based on whether the firm adjusts product quality and prices according to consumer feedback from reviews: a static model (as a baseline) and a dynamic model. In the static model, the firm decides product quality, prices, and production quantity in the first stage, while in the second stage, the firm does not enhance product quality, and prices remain unchanged. In the dynamic model, in the first stage, the firm decides initial product quality and pricing, then in the second stage, adjusts product quality based on consumer feedback and sets pricing accordingly. We propose a distributionally robust optimization (DRO) method to address this problem, obtaining a closed-form solution for the expected profit function under the worst distribution, making it easy to determine the optimal decision. Through numerical simulation analysis, we find that the firm implementing dynamic decisions always make higher profits compared to those using static decisions. This highlights the superiority of dynamic decisions in adapting to market changes and improving product quality. We also analyze the impact of expected and standard deviation of potential market demand, as well as consumer private assessment weight, on business decisions and profits. Our research provides effective support for firms with limited market information, enabling them to better formulate joint pricing, quality, and production decisions.

Rotary friction welding applied to Cu11.8Al0.45Be shape memory alloy

The feasibility of welding a CuAlBe SMA by continuous drive friction welding was evaluated. The metallurgical state (annealed/quenched) before welding and frictional pressure (5 and 10 MPa) were varied and their effects on joint quality were analyzed. Static tensile tests, microhardness, thermal analysis by DSC, and optical microscopy were carried out to characterize the welded joint. The results indicated joints of excellent thermomechanical quality. The welding zones are well-defined, narrow, and have a very refined microstructure compared to the base metal. The phase transition temperatures along the welded assemblies were not changed when welding was performed on the quenched samples, except in the welding zone of the sample welded with 10 MPa. Maximum tensile strength was obtained by using maximum friction pressure during welding of the annealed alloy (quenching after welding). To fill the gap in bibliographical research in this field of study, this work innovatively presents the possibility of welding Cu-based SMAs by rotary friction, including the welding of quenched parts without the need for subsequent heat treatments and without compromising the shape memory effect.

Research on technological parameters affecting the quality of adhesive joints in casting model assemblies and assessment of their operational properties in liquid and humid environments

Modern casting model kits, often created using adhesive technologies, can experience deformations leading to warping and even destruction. This can occur due to differences in thermal expansion and moisture absorption rates between the material and the adhesive. The study evaluated the behavior of the adhesive joint in model kit elements under operational conditions in liquid and humid environments, assessing the hardness and strength of the joint. The analysis revealed a correlation between the density of the plastic and the quality of the adhesive joint.