Weld Interface Research Articles

Linear friction welding of T-Joints in low carbon steel: Effect of welding parameters on joint quality

Linear friction welding (LFW) is a well-established solid-state joining technique. However, its application in T-joint configurations remains unexplored. This study investigated the effects of welding parameters, such as oscillation direction, upset, and applied pressure after oscillation, on linear friction welded (LFWed) T-joints using low-carbon steel SM490A. The flash ejection behavior, flash profiles, microhardness, microstructure at the welding interface, and tensile properties of the joints were evaluated under various welding conditions. The results indicated that flash symmetry was lower along the oscillation direction and higher perpendicular to it. Short-side oscillation produced more homogeneous flash ejection compared to long-side oscillation. No distinct softening zones were observed in the hardness profiles of the LFWed T-joints. The microstructure at the welding interface consisted of martensite, bainite, and ferrite, indicating that the weld region reached temperatures above the A1 temperature. The martensite fraction and hardness increased with higher upset and applied pressure after oscillation. Tensile tests revealed 100 % joint efficiency across all welding conditions, with ductile fracture occurring in the base metal due to the absence of welding defects and increased hardness at the interface.

Microstructure and mechanical-property evolution of the explosive welding joint from the same RAFM steels under explosive welding and post-weld heat treatment

This study investigated the morphological evolution behaviors and the mechanical property of the weld interface during explosive welding for the flyer plate and base plate sourcing from the same reduced activation ferrite/martensitic (RAFM) steel. The relationship between fine-grain formation and the occurrence of dynamic recrystallization was analyzed based on the strain and temperature field distributions at the explosive-weld interface. Although post-weld tempering (PWT) treatment eliminated bent martensite laths, but it did not eliminate fine equiaxed grains and δ ferrite grains near the explosive-weld interface; therefore, the PWT treatment improved the mechanical properties of the explosive-weld RAFM steel joint only minimally. However, implementation of a normalizing process after the explosive welding process (“PWN” treatment) significantly eliminated the gradient structure and the residual δ ferrite grains at the explosive-weld interface of the RAFM steel joint. Based on the PWN state, the inclusion of a tempering treatment (“PWNT” treatment) promoted the uniform precipitation of M23C6 carbides, which significantly improved the tensile strengths of the explosive-weld RAFM steel specimens under both room and high temperatures. To study the influence of different microstructures on the plastic deformation behavior at the explosive-weld interface, the representative volume element (RVE) models basing on crystal plasticity finite element (CPFEM) method was constructed for different post-weld heat treatments (PWHTs). At the explosive-weld interface of the PWT-state RAFM steel joint, the plastic deformation was mainly concentrated in the δ ferrite grains, rather than in the fine equiaxed grains. In addition, only minimal deformation concentration was observed for the PWNT-state RAFM steel joint. In order to reveal the independent influence of the fine equiaxed grains at the weld interface on the mechanical properties of explosive-weld RAFM steel joint, the microstructural and mechanical distinctions between the RAFM steel joints in the N-PWT and PWNT states were investigated detailly. Finally, through optimization of the PWHT method, an explosive-weld RAFM steel (PWNT state) joint with a uniform microstructure and ideal mechanical properties was obtained.

Physical Heat Cycle Measurement of Resistance Spot Welding

Resistance spot welding (RSW) is still the ideal joining method in the automotive industry. Mostly steel sheets are used in the car body, so overlap and layering are required for welding or riveting, as spot welding provides simultaneous clamping force with interfacial welding to ensure the required strength and quality. A fundamental understanding of heating and cooling rates in thermal distributions is essential for predicting microstructure formation in the weld and the heat-affected zones (HAZ) of RSW joints. The ability to measure the heat cycle in the RSW process can be valuable in weld control and welding parameter optimization. RSW parameters can be optimized through tensile shear tests and microscopic investigations. Heat cycle measurement (HCM) demonstrates the welding consequences in terms of the change in mechanical properties and microstructural formations. The accuracy of cooling rate measurements including t8/5 cooling time is very important to predict the microstructural evolution in the HAZ, however, the thermocouple measurement raises numerous challenges due to the high temperature gradient and small weld and HAZ size. During our investigations heat cycle measurement has been conducted experimentally by a K-type thermocouple. The data logger is connected to the output of the thermocouple for recording the voltage to measure the temperature distributions as a function of both time and position during the welding process. Measurement results of 1 mm thick martensitic MS1400 steel overlapped RSW joints are discussed, and the HCM curve of heating and cooling rates of the spot-welding process is presented. The heat cycle during RSW was measured with two different welding parameter combinations. In addition to welding current, welding time, and electrode force, pulsation has shown disparate curves. Numerous experiments have been attempted to measure the heat cycle in HAZ sub-zones due to the difficulty of positioning the thermocouple accurately, uppercritical HAZ, intercritical HAZ, and subcritical HAZ were investigated and measured in both welding parameter combinations. Difficulties were encountered in the experimental work as a result of the instantaneous welding time and the vibration resulting from the passage of alternating electrical current between the two electrodes. A magnetic field is generated that affects the thermocouple measurement and appears as a noisy curve that is filtered out and smoothed. Joule heat, interfacial heat generation, and cooling effects of electrodes are also considered in the experiment.

Analysis of Energy Flow to the Interface Microstructure and Its Effect on Weld Strength in Ultrasonic Additive Manufacturing

Ultrasonic additive manufacturing (UAM) is a process used for the three-dimensional printing of metal foil stock that can produce near-net-shaped metallic parts. This work details the development of an energy-based tool to identify the relationships between input energy, energy stored in the interface microstructure, and the strength of the weld interface in UAM. The stored energy in the grain boundaries of the crystallized grains in the interface microstructure are estimated using the Read–Shockley relationship. The energy stored in the interface is found to be positively correlated with the resulting weld strength. An energy flow diagram is developed to map the flow of energy from the welder to the workpiece and quantify the key participating energies such as the energy of plastic deformation, energy stored in the interface microstructure, energy required for asperity collapse, and heat generation. A better understanding of the flow of energy in UAM can assist in optimizing the process to maximize the portion of energy input by the welder that is used for bond formation.

Optimization of polypropylene high-strength injection molding welding and interface structure analysis

Secondary injection molding is an effective method for joining polymer parts, where the weld interface plays a critical role in the overall performance of the part. This study discusses the influence of injection molding parameters on the interface strength of polypropylene and polypropylene (PP-PP) secondary injection molding and analyzes the welding interface structure. The injection molding parameters for PP-PP were optimized using the Taguchi method and the signal-to-noise ratio (S/N). The optimal injection molding parameters were determined to be a mold temperature of 120°C, injection temperature of 350°C, and injection speed of 100 mm/s. The interface tensile strength was measured at 33.42 MPa, corresponding to 98.1% of the tensile strength of the base material. Among these parameters, mold temperature has the greatest influence on the strength of the welding interface. Secondly, polarizing microscopy, scanning electron microscopy (SEM), and Fourier transform infrared spectroscopy (FTIR) were employed to observe and analyze the crystal structure and fracture failure modes at the interface. The results indicate that elevated injection molding parameters promote the formation of crystal nuclei and spherulite growth at the secondary melt interface, with the spherulite size at the interface significantly affecting the interface strength. This study offers valuable reference for the welding of other polymers and fiber-reinforced materials.

Numerical simulation and modeling of the trielectrode-coupled corrosion mechanism at the laser-welded interface of N80 steel

Laser welding, a prevalent technique in automotive structure manufacturing, can introduce compositional disparities and stresses within the weld zone, exacerbating corrosion complexity at the weld interface. This paper develops a triple galvanic corrosion model for N80 steel welds under stress conditions, leveraging the COMSOL software for simulations. The findings demonstrate that, within the elastic stress range, an elevation in stress intensifies the overall electrode surface potential, ultimately transitioning into plastic stress and fostering a more negative potential. This, in turn, amplifies the cathode-anode potential difference, rendering the material more susceptible to corrosion. The deeper the depression between the weld zone and the heat-affected zone, the higher this potential difference becomes, exacerbating the corrosion risk. Under stress, the corrosion rate markedly surpasses that observed in unstressed conditions. During the 160 day corrosion period, the weld seam and heat affected zone undergo a transition from plastic strain to elastic strain, while the base metal zone experiences both plastic strain and elastic strain simultaneously. This dynamic strain evolution leads to temporal variations in the stress-induced cathode-anode potential differences. In comparison to stress-free corrosion scenarios, the impact of stress on the cathode-anode potential difference initially intensifies, yet this effect tapers off over time.

Experimental study under thermal shock environment to investigate effect of welding width on properties of ultrasonically welded joints of multiple copper cables

Based on the ultrasonic welding technology, this study uses three different welding widths to weld copper cables with different specifications. The influence of welding width on the mechanical properties and microstructure of each group of welded joints was systematically studied for the first time. The thermal shock test was carried out for each group of welded joints under optimum welding width to simulate the influence of severe temperature change environment on joint performance. It is found that the cross-sectional area of joint is 20 mm2 and optimal welding width of joint composed of two and three cables is 7 mm. The optimal welding temperature of the joint composed of four cables is 5 mm. Under the optimal welding width, the average shear strength of two-cable joint reaches 309.4 N. The four-cable joint is only 232.2 N. Moreover, the welding strength weakens significantly as the number of cables and the peak temperature decreases. The high temperature of bonding interface is the key factor to form a good weld. The peak temperature during welding is negatively correlated with the porosity of joint and positively correlated with peeling strength of joint. In addition, the morphology of ultrasonically welded joints has changed obviously after thermal shock test. With the participation of oxygen, the surface of welded joint is gray and bright brass, while the interior of joint is purple due to lack of oxygen. Moreover, the phenomenon of atomic diffusion and thermal expansion generates joints which were initially in a mechanically interlocked form and welding interface of the metallurgical bond under the action of high temperature. So the maximum joint peel strength is slightly improved.

Study on thermal-assisted underwater friction stir welding for carbon fiber-reinforced polyetherimide

Friction stir welding (FSW) of carbon fiber-reinforced thermoplastic has shown attractive applications in industrial fields. However, the heat input during the FSW is hard to control, which leads to significant material loss and carbon fiber damage. In this paper, a carbon fiber-reinforced polyetherimide (CF-PEI) plate is joined via thermal-assisted underwater friction stir welding (UFSW). The evaluation of heat-assisted UFSW joints is conducted by studying the surface morphology, microstructure of the weld interface, the state and distribution of carbon fibers, and tensile analysis. The findings indicated that water can reduce heat input, and the water temperature has a significant impact on the weld properties. Specifically, at a water temperature of 60°C, there is a considerable reduction in material loss and carbon fiber damage. The study also reveals that this temperature facilitates the interweaving of carbon fibers into a stable structure at the interface and their integration with the PEI substrate. This reduces the inhibition of the material on carbon fiber elongation, ultimately enhancing the bonding interface and improving tensile shear properties. The maximum tensile strength value of the welds reached 33.6 MPa, equivalent to 79.6% of the CF-PEI sheet. Compared to FSW, joint tensile strength is increased by 45.5%.

Investigation on effects of nano-reinforcement on the mechanical properties, fatigue, and microstructural analysis of dissimilar AA6061- Mg AZ31B weld joints

Weld joints have been subject to substantial improvement in mechanical durability and wear resistance in recent years. This research work challenge can be answered by incorporating nano-materials into the weld zone. Mechanical and metallurgical aspects of friction stir welded (FSW) butt joints made of AA6061 aluminum and Mg AZ31B alloys have been examined in this work, both with and without the use of naturally derived biochar nanoparticles. The biochar particle was extracted from rice husk. Throughout the whole weld joint manufacturing process, a tool with a rotational speed of 1400 rpm, a welding speed of 40 mm min−1, and a tapered pin profiled tool were employed. During the joint fabrication process, the constant axial load of 7 kN, plunge depth of 0.2 mm, and constant dwell time of 0.3 s were also maintained. In order to improve the mechanical attributes of the weld joints, different wt% of biochar such as 1%, 2%, and 3%, were applied at the interface region of the weld joints. The experimental results revealed that the percentage of reinforced nano-materials plays a significant effect in improving the weld joint qualities. The testing results of reinforced friction stir-welded joint qualities were compared to those of simple friction stir welded joints made without and with adding the nanoparticles. The best results were obtained when 2 wt% of biochar particles was added to the weld interface region. The presence of biochar nano-particles, in addition to their contribution to increased grain refinement in the weld nugget region, was also seen in the region. It was discovered that the event distribution of particles at the nugget zone significantly enhanced the mechanical and wear resistance qualities of the weld joints that were manufactured. The optical microscope was used to analyze the microstructures in the weld nugget region, and a scanning electron microscope (SEM) was utilized to examine the fracture analysis of the tensile samples. The presence of 2 wt% biochar particles in the weld nugget region resulted in a considerable increase in the mechanical characteristics of the weld connections. The ultimate tensile strength, hardness, and yield strength of the weld nugget results 197 MPa, 173 HV, 163 MPa. Overall, when compared to the qualities of the base material and plain weld joints. The mechanical properties and wear resistance of the weld joints have improved significantly. When biochar particles were used as reinforcement particles during the fabrication phase of the joint, a mechanism for pinning was observed in the weld microstructure.

Evaluation of corrosion properties of TA2-Q345 explosive composite plate at different heat treatment temperatures

This study investigated the effects of post-weld heat treatment (PWHT) at 500 °C, 600 °C, 700 °C, and 800 °C on the microstructure and corrosion performance of the TA2-Q345 explosive composite plate, with TA2 as the flyer plate and Q345 as the base plate. X-ray diffraction (XRD), optical microscopy (OM), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) analyses were performed, alongside electrochemical experiments. The explosive welding interface of the TA2-Q345 composite plate exhibited a characteristic wavy structure, which indicated high welding quality. The XRD results indicated that the PWHT temperature significantly affects both the phase structure and the intensity of the diffraction peaks of the oxide film. Additionally, the porosity calculations demonstrated that the sample subjected to PWHT at 500 °C exhibited the lowest porosity in the surface oxide film, resulting in a denser oxide film that effectively enhanced corrosion resistance. However, as the temperature continued to rise, defects such as craters, bulges, and delamination between the oxide film and the titanium matrix were observed. The results of the electrochemical analysis indicated that, compared to untreated samples, the PWHT samples demonstrated improved corrosion resistance. Specifically, the sample with PWHT at 500 °C has the lowest corrosion current density (icorr) of 6.1892E-06 A/cm2, while the untreated sample has the highest icorr of 6.3577E-05 A/cm2, indicating that 500 °C is the optimal temperature. The corrosion process involved the hydrolysis of titanium chloride to form a TiO2 film and localized corrosion of the TiO2 protective film. The corrosion products composed of mainly C, O, and Ti were dispersed on the surface of PWHT samples.

A study on the feasibility of friction stir welding in joining dissimilar metals for SS400 and Ti-6Al-4V

Abstract This study designed friction stir multi-pass welding machine to conduct friction stir welding on carbon steel/titanium alloy clad sheets. The experimental process utilized the pin and pinless tools. The results demonstrate that the two dissimilar materials can be welded using the assembly-embedded rod pinless tool under the following welding conditions: a rotational speed of 1200 rpm, a downward force of 4 kN, a welding speed of 15 mm/min, and tool offset distances of 5 and 10 mm. Furthermore, this study investigated the microstructure and mechanical properties of the weld. In addition, the peak temperature measured at the joint interface exceeded the β phase transition temperature of the titanium alloy and surpassed 1000°C. The shear tensile test shows the weld’s failure load was about 4300 N. The intermetallic compound at the welding interface has a microhardness value of approximately 400 Hv. According to the results of SEM observations and EDS composition element analysis, the elements of low carbon steel and titanium alloy at the interface of the clad sheet diffused and formed Fe-Ti intermetallic compounds.

Achievement of superb-strength lap joint via opposite-directions flowing friction stir lap welding of 2024 aluminum alloys

It is common for the rotating pin largely plunging into lower sheet to break up lap interface of Friction Stir Lap Welding (FSLW) joint, but the unavoidable up-bending morphology of hook outside Nugget Zone (NZ) largely reduces the joint bearing ability. Based on the novel Opposite-directions Flowing FSLW (OF-FSLW) by the self-developed rotating tool with an X-shaped right-left thread pin, the 2024 aluminum alloys lap joint was successfully welded in this study. The migration law of lap interface during welding was investigated by the experimental and numerical methods, and then how the rotating pin and its rotating velocity affect the formation and strength of OF-FSLW joint was further analyzed. The results show that the Material Concentrated Zone (MCZ) which formed above the original lap interface made the hook bend downward, the NZ greatly enlarged and the beginning part of cold lap compressed and thickened, thereby heightening the joint bearing ability. For the OF-FSLW joint, its maximum tensile strength was 403 MPa, and the corresponding joint efficiency of 90.8% was an incredible and superb value for the 2000 series heat-treatment strengthened aluminum alloys friction stir welded joint. The OF-FSLW technology by the rotating tool with an X-shaped right-left thread pin is proven to be a greatly effective approach for manufacturing the aluminum alloys lap joint with superb strength.

Adaptively remeshed multiphysical modeling of resistance forge welding with experimental validation of residual stress fields and measurement processes

Welding processes used in the production of pressure vessels impart residual stresses in the manufactured component. Computational modeling is critical to predicting these residual stress fields and understanding how they interact with notches and flaws to impact pressure vessel durability. In this work, we present a finite element model for a resistance forge weld and validate it using laboratory measurements. Extensive microstructural changes, near-melt temperatures, and large localized deformations along the weld interface pose significant challenges to Lagrangian finite element modeling. The proposed modeling approach overcomes these roadblocks in order to provide a high-fidelity simulation that can predict the residual stress state in the manufactured pressure vessel; a rich microstructural constitutive model accounts for material recrystallization dynamics, a frictional-to-tied contact model is coordinated with the constitutive model to represent interfacial bonding, and adaptive remeshing is employed to alleviate severe mesh distortion. An interrupted-weld approach is applied to the simulation to facilitate comparison to displacement measures. Several approaches are employed for residual stress measurement in order to validate the finite element model: neutron diffraction, the contour method, and the slitting method. Model-measurement comparisons are supplemented with detailed simulations that reflect the configurations of the residual-stress measurement processes themselves. The model results show general agreement with experimental measurements, and we observe some similarities in the features around the weld region. Factors that contribute to model-measurement differences are identified. Finally, we conclude with some discussion of the model development and residual stress measurement strategies, including how to best leverage the efforts put forth here for other types of related weld problems.

Enhancing bending strength in continuous drive friction welding of PEEK polymer cylinders through the innovative progressively increased welding area method

The continuous drive friction welding (CDFW) stands out for its low energy consumption within the welding realm. Polyetheretherketone (PEEK) represents a high-performance engineering thermoplastic, falling under the polyaryletherketone family. Renowned for its outstanding mechanical, thermal, and chemical attributes, PEEK finds utility across a diverse array of industries. However, the discovery of numerous voids at the weld interface has revealed limitations in the mechanical properties of PEEK welded samples. This study introduces an innovative approach named progressively increased welding area (PIWA) method, to mitigate voids within the weld interface. In general, the Taguchi method was used to optimize the process parameters of CDFW of dissimilar PEEK round rods to reduce random efforts by the trial-and-error method. It was found that the proposed PIWA method can definitely enhance the bending strength of rotational friction welded samples due to reduction of voids inside the weld interface. The optimal process parameters for the CDFW with the PIWA method involve a rotational speed of 2500 rpm, a cone angle of 120°, a cone top width of 8 mm, and a feed rate of 0.1 mm/s. The most influential factor affecting the bending strength of the PEEK welded samples is the feed rate, followed by cone angle, rotational speed, and cone top width. Specifically, the contribution ratios for feed rate, cone angle, rotational speed, and cone top width are about 71 %, 20 %, 7 %, and 2 %, respectively. The confirmation tests showed that the bending strength of the PEEK welded samples using optimal process parameters can be increased by approximately 68 % compared with the maximum bending strength of 180 MPa using the conventional method with a cone angle of 180° The proposed PIWA method has industrial applicability and practical value because this technique can enhance the mechanical properties of PEEK welded samples under low environmental pollution and energy consumption.

Fracture mechanisms of Al-steel resistance spot welds: The role of intermetallic compound phases

This study explores the mechanical and metallographic characteristics of Al-Steel dissimilar resistance spot welds (RSW), with a particular focus on the intermetallic compound (IMC) phases and their impact on fracture mechanisms. Detailed metallographic analyses and novel miniature lap shear tests with in-situ Digital Image Correlation techniques were conducted to observe the crack propagation behavior. The findings revealed that the IMC phases significantly influence the crack path and fracture mechanisms, leading to variations in fracture energy. Specifically, three distinct IMC phases were identified at the weld interface, each exhibiting unique structural and mechanical properties, with corresponding fracture energies of approximately 0.03 kJ/m2, 1.1 kJ/m2, and 7.5 kJ/m2. These variations highlight the critical role of the IMC phase in determining the fracture behavior of the weld. The study further supported the development and validation of a finite element (FE) model, incorporating a Cohesive Zone Model to simulate debonding behavior and the Hosford-Mean fracture criterion to predict ductile fracture in the Al fusion zone, thereby successfully linking local material characteristics to mechanical properties.

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.

Realizing ultrahigh strength and excellent stability of ultrasonically welded joints upon co-consolidating an extra resin layer (eRL) on the thermoplastic composites

Ultrasonic welding is a promising technique well-suited for joining thermoplastic composites. On the way towards upscaling and industrializing this technology, it is crucial to improve the welding process stability and joint structure integrity. Herein, a novel-structured carbon fiber (CF)/polyetherimide (PEI) composite topped with an extra PEI resin layer was developed using a co-consolidation process for ultrasonic welding. The experimental results proved that the extra resin layer effectively promoted the heat generation efficiency at the joining interface, improved the quality and uniformity of the welding line, as well as played a thermal barrier role to prevent composite overheating. This significantly improved the welding stability and the mechanical performance of the joints. For example, a superior lap-shear strength of 45.9 MPa was obtained by simultaneously optimizing the thicknesses of the extra resin layer and the energy director. Moreover, the bending and squeezing-out of carbon fibers at the welding interface were successfully eliminated.

Ultrasonic welding of continuous carbon fiber reinforced PEEK with embossed energy directors

Ultrasonic plastic welding (UPW) is an efficient and environmentally friendly method for joining carbon fiber reinforced thermoplastic (CFRTP). A crucial aspect of UPW is the design of the energy director (ED). In this study, ultrasonic embossing technology was used to process flat EDs to obtain a new type of ED, named embossed ED. The effect of embossed EDs on the joint formation in ultrasonic welding of continuous carbon fiber reinforced PEEK was investigated in terms of tensile shear properties, macro and micro-morphologies, and fracture morphology. The results show that the use of embossed EDs makes a more homogeneous temperature distribution at the welding interface which significantly reduces defects in the joint. The use of embossed EDs increases the failure load of welded joints by about 50 % (up to 39.6 MPa) and reduces the variation of the joint quality compared with the use of flat EDs. In the optimal condition, the joints made with embossed EDs experiences interlaminar failure of the base material.

Microstructure and properties of Mg/Ti joint welded by resistance spot welding with an aluminum interlayer

Magnesium alloy AZ31B and titanium TA2 were welded by resistance spot welding technology employing an interlayer of aluminum foil and asymmetric electrodes. The microstructure of the joint was observed, with an analysis conducted on the impact of welding current and welding time on the tensile shear load of the joint. During the welding process, the aluminum interlayer melted and blended with the molten magnesium alloy, leading to the formation of a eutectic layer consisting of Mg17Al12 and (Mg) in close proximity to the welding interface. As the increasing of welding current or the extending of welding time, there was an initial increase followed by a slight decrease in the tensile shear load of the AZ31B/TA2 joint. At a welding current of 16 kA, the tensile shear load of the joint achieved the maximum, which was approximately 6.48 kN. The findings suggest that it is effective to use an aluminum foil as an intermediary to regulate the metallurgical reaction at the interface and utilize nonsymmetrical electrodes for thermal compensation in the resistance spot welding between titanium and a magnesium alloy.

In situ construction of sequential nanoreactor with built-in catalyst as self-supporting cathode for lithium–sulfur batteries

Architecture design and optimization are essential in improving the performance of lithium–sulfur batteries. Herein, an all-in-one sequential architecture of CoSe catalysts confined in MOF-derived nanoreactors (NRs) interfacially welded on carbon cloth (CC) is constructed using an in situ strategy (abbreviated: S@CoSe-NRs/CC). NRs with built-in CoSe (CoSe-NRs) have special microenvironments and domain-limited catalysis for efficient adsorption, catalysis, and deposition. The weld interface between the CoSe-NRs and the CC forms a continuous and robust all-in-one conductive network. Both experiments and theoretical calculations demonstrate that the S@CoSe-NRs/CC offers stable interconnectivity and efficient space utilization for high sulfur loads and rapid ion transport supply, providing a high initial discharge capacity of 1320 mA h g−1 at 0.1 C with a capacity decay rate as low as 0.003% per turn after 1000 cycles. This study offers unique insights and revelations for realizing the rational design of high-performance energy storage devices.