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Advanced Welding Technology and Its Applications
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Advanced Welding Technology and Its Applications

A special issue of Applied Sciences (ISSN 2076-3417). This special issue belongs to the section "Applied Industrial Technologies".

Deadline for manuscript submissions: 20 January 2026 | Viewed by 6781

Special Issue Editor

Dr. Radoslaw Winiczenko

E-Mail Website
Guest Editor
Institute of Mechanical Engineering, Warsaw University of Life Sciences, 02-787 Warsaw, Poland
Interests: friction welding; ductile irons; TEM; SEM; MAR; mechanical properties; microstructure; FEA; optimization; genetic algorithms

Special Issue Information

Dear Colleagues,

This Special Issue, entitled "Advanced Welding Technology and Its Applications", highlights the latest advances in various welding processes across the field, including solid-state welding, electron beam welding, laser welding, magnetic arc welding, the ultrasonic welding process, thermal spraying, and experimental processes. Advanced welding technology are fundamental in advanced engineering materials to expand their applications. Moreover, they provide extraordinary benefits such as component cost reduction, increased productivity, and unique joint properties. This Special Issue will provide an overview of various welding processes used to join light alloys, new composites, heavy tungsten alloys and ceramics. The influence of various process parameters, structural morphology and changes in mechanical properties will be important issues discussed in the publications. The Special Issue will include current problems related to joining materials using advanced techniques, as well as innovative solutions in direct industrial applications.

The main topics covered by the Issue include:

  • Technologies for welding dissimilar and difficult-to-weld materials;
  • The latest research on solid-state welding processes (e.g., friction stir welding);
  • Structure and mechanical properties of welded joints;
  • Characterization of innovative materials to produce welding joints;
  • Process optimization in experimental and simulation terms;
  • Finite-element analysis of thermo-mechanical processes.

Dr. Radoslaw Winiczenko
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • solid-state welding
  • laser welding
  • fusion welding
  • arc welding
  • dissimilar materials
  • mechanical properties
  • microstructure
  • FEA
  • optimization

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Published Papers (5 papers)

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Research

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18 pages, 39111 KB  
Article
Impact of Beam Shape and Frequency on Weld Seam Geometry and Penetration Depth Using a Coherent Beam Combining Laser
by Karthik Ravi Krishna Murthy, Reza Sanei, Abhay Sharma, Simon Olschok and Uwe Reisgen
Appl. Sci. 2025, 15(17), 9432; https://doi.org/10.3390/app15179432 - 28 Aug 2025
Viewed by 432
Abstract
The geometry and quality of a weld seam are critical factors in laser beam welding, influencing mechanical performance and structural integrity. Dynamically modulated laser beams provide a precise means of tailoring energy input in high-power laser welding processes. This study investigates the influence [...] Read more.
The geometry and quality of a weld seam are critical factors in laser beam welding, influencing mechanical performance and structural integrity. Dynamically modulated laser beams provide a precise means of tailoring energy input in high-power laser welding processes. This study investigates the influence of beam shape and modulated frequency on weld seam geometry, penetration depth, and capillary behaviour using a coherent beam combining (CBC) laser system from Civan Lasers. Three beam intensity distributions—single point, line–point–line (LPL), and boomerang—were applied across a modulation frequency range of 1, 10, and 100 kHz during the welding of duplex and austenitic stainless steels. High-speed imaging captured real-time capillary dynamics, and the data were analysed to assess capillary stability, measure capillary diameter, and determine the capillary front angle as a function of frequency and beam shape. Transverse cross-sections of the welds were prepared to evaluate seam geometry and microstructure. The results show that beam shape significantly affects energy distribution and weld profile, while modulation frequency critically influences capillary behaviour and penetration characteristics. These findings highlight the critical role of dynamic beam shaping and frequency modulation in optimizing laser welding processes for material-specific performance, offering a versatile platform for advancing precision manufacturing using CBC technology. Full article
(This article belongs to the Special Issue Advanced Welding Technology and Its Applications)
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15 pages, 13534 KB  
Article
Mechanical Properties Analysis of WAAM Produced Wall Made from 6063 Alloy Using AC MIG Process
by Ivica Garašić, Mislav Štefok, Maja Jurica, Davor Skejić and Mato Perić
Appl. Sci. 2025, 15(12), 6740; https://doi.org/10.3390/app15126740 - 16 Jun 2025
Viewed by 860
Abstract
Wire and arc additive manufacturing (WAAM) is a promising method of producing medium- and large-sized aluminum alloy structures, though it faces challenges such as porosity, residual stresses and inconsistent mechanical properties. This study investigates the effect of current type (AC and DC MIG [...] Read more.
Wire and arc additive manufacturing (WAAM) is a promising method of producing medium- and large-sized aluminum alloy structures, though it faces challenges such as porosity, residual stresses and inconsistent mechanical properties. This study investigates the effect of current type (AC and DC MIG welding) and polarity balance (influencing the duration of the positive/negative period of the cycle) on the mechanical and microstructural properties of 6063 aluminum alloy walls produced by WAAM. A TiB2-refined Al–Mg–Si (6063) filler wire, specifically developed for arc-based processing, was used. Tensile tests, Vickers hardness measurements (HV5), optical microscopy and X-ray diffraction based on cosα method were used to evaluate performance in terms of strength, ductility, hardness, grain structure, porosity and residual stress. The results showed that the balance of AC polarity significantly affects wall geometry, porosity and grain structure. Increasing the negative polarity period resulted in taller and narrower walls, while the widest walls were produced with increased positive polarity. Residual stress measurements revealed a tensile–compressive–tensile distribution, with the DC-MIG samples showing the highest surface stress values. The highest tensile strength (172 MPa) was measured in the lower region of the DC-MIG sample, suggesting that areas near the substrate benefit from faster cooling. Full article
(This article belongs to the Special Issue Advanced Welding Technology and Its Applications)
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17 pages, 2815 KB  
Article
Multi-Objective Optimisation of Welding Parameters for AZ91D/AA6082 Rotary Friction Welded Joints
by Radosław Winiczenko, Andrzej Skibicki and Paweł Skoczylas
Appl. Sci. 2025, 15(3), 1477; https://doi.org/10.3390/app15031477 - 31 Jan 2025
Viewed by 1127
Abstract
Recently, rotary friction welding has been used to join magnesium alloys. FRW uses friction heat to bond magnesium alloys with aluminium alloys. Combining these light alloys can provide many promising applications in the industry. The welding parameters such as friction and upsetting force, [...] Read more.
Recently, rotary friction welding has been used to join magnesium alloys. FRW uses friction heat to bond magnesium alloys with aluminium alloys. Combining these light alloys can provide many promising applications in the industry. The welding parameters such as friction and upsetting force, rotational speed, and welding time play a significant role in determining the joint strength. The paper presents a new approach to multi-objective optimisation of friction welding process parameters for AZ91D/AA6082 alloy joints. Multi-objective optimisation is based on artificial neural networks and genetic algorithms as non-conventional AI techniques. The methods were used to determine the following optimal welding process parameters: friction force, upsetting force and friction time for simultaneously maximised tensile strength and minimised metal loss (shortening) during welding. The ultimate tensile strength and metal loss of the friction welding joints were studied numerically and experimentally. Moreover, the influence of welding parameters on the ultimate tensile strength and shortening of friction joints was also studied. A genetic algorithm successfully found a set of welding parameters for which the joint strength increases from 24 to 81 MPA and the joint shortening decreases from 8.25 to 0.23 mm. The results show that a low friction force and upsetting force give a high value of tensile strength and the lowest shortening of the bimetal joints. Full article
(This article belongs to the Special Issue Advanced Welding Technology and Its Applications)
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16 pages, 6204 KB  
Article
Development of an Artificial Neural Network Model to Predict the Tensile Strength of Friction Stir Welding of Dissimilar Materials Using Cryogenic Processes
by Mingoo Cho, Jinsu Gim, Ji Hoon Kim and Sungwook Kang
Appl. Sci. 2024, 14(20), 9309; https://doi.org/10.3390/app14209309 - 12 Oct 2024
Cited by 5 | Viewed by 1653
Abstract
The objective of this study was to develop an artificial neural network (ANN) model for predicting the tensile strength of friction stir welding (FSW) joints between dissimilar materials, with a particular focus on aluminum and copper, using cryogenic processes. The research addresses the [...] Read more.
The objective of this study was to develop an artificial neural network (ANN) model for predicting the tensile strength of friction stir welding (FSW) joints between dissimilar materials, with a particular focus on aluminum and copper, using cryogenic processes. The research addresses the challenges posed by differences in material properties and the complex nature of FSW, where traditional experimental methods are time-consuming and costly. FSW experiments were conducted under a variety of conditions, and the resulting temperature data were utilized as input for a heat transfer analysis. The maximum temperature and temperature gradient obtained from the analysis were employed as input variables for training the ANN. The ANN was optimized using the Hyperband tuner and validated against experimental results. The model successfully predicted tensile strength with an average error of 5.4%, demonstrating its potential for predicting mechanical properties under different welding conditions. This approach offers a more efficient and accurate method for optimizing FSW processes. Full article
(This article belongs to the Special Issue Advanced Welding Technology and Its Applications)
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Review

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18 pages, 5985 KB  
Review
Research Status and Progress of All-Position Narrow-Gap GMAW for Pipelines
by Wenji Liu, Qing Li, Jianfeng Yue, Peng Zhu and Bing Li
Appl. Sci. 2025, 15(5), 2270; https://doi.org/10.3390/app15052270 - 20 Feb 2025
Cited by 1 | Viewed by 1017
Abstract
During the all-position narrow-gap welding process of pipelines, welding defects tend to occur in non-flat welding positions, constraining the quality and efficiency of pipeline construction. This paper addresses the sidewall and interlayer lack of fusion defects that commonly arise in all-position pipeline welding. [...] Read more.
During the all-position narrow-gap welding process of pipelines, welding defects tend to occur in non-flat welding positions, constraining the quality and efficiency of pipeline construction. This paper addresses the sidewall and interlayer lack of fusion defects that commonly arise in all-position pipeline welding. Based on the research achievements of scholars and engineering technicians at home and abroad in recent years, the paper summarizes the influence laws of droplet transfer characteristics, arc morphology, and molten pool behavior on weld seam formation under different welding positions during gas metal arc welding. Additionally, the paper explores strategies for optimizing weld bead formation, including optimizing welding process parameters, controlling the molten pool flow with an external magnetic field, and using laser–arc hybrid welding. The paper points out the development trends of all-position pipeline welding technology, providing technical guidance and problem-solving ideas for alleviating the flow of the molten pool and optimizing the formation of all-position weld seams in engineering practice. Furthermore, it offers direction for scientific research for relevant researchers. Full article
(This article belongs to the Special Issue Advanced Welding Technology and Its Applications)
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