Advances in Dissimilar Metal Joining and Welding, 2nd Edition

Special Issue Editors


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Guest Editor
Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), University of Porto, 4200-465 Porto, Portugal
Interests: dissimilar joining; structural integrity; friction stir welding; fatigue; fracture
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Faculty of Engineering, University of Porto, 4200-465 Porto, Portugal
Interests: structural integrity; computational mechanics; fracture mechanics; fatigue; digital-twins
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Dissimilar material welding holds immense relevance in contemporary manufacturing due to its pivotal role in integrating diverse materials to meet specific engineering requirements. As industries increasingly demand lighter, stronger, and more versatile components, dissimilar material welding facilitates the construction of advanced structures and assemblies. However, it poses unique challenges stemming from the inherent differences in physical properties, thermal expansion coefficients, and metallurgical behaviors among dissimilar materials. Achieving robust welds while minimizing distortion, residual stresses, and intermetallic compound formation remains a daunting task. Moreover, ensuring the long-term structural integrity and reliability of dissimilar weld joints under varying operating conditions further compounds the challenges. Addressing these complexities requires interdisciplinary research efforts, innovative welding techniques, and a comprehensive understanding of material science and engineering principles, highlighting the significance of ongoing exploration and advancement in this field.

The Journal of Manufacturing and Materials Processing presents a special issue focused on dissimilar metal joining and welding. This special issue examines the latest advancements and practical implications in joining different metals, metal polymer joints and metal composite joints, crucial across industries like automotive, aerospace, and electronics.

Aligned with the journal's scope, this special issue addresses fundamental challenges and innovative solutions in manufacturing processes and materials engineering. Contributors explore diverse methods including friction stir welding, laser welding, ultrasonic welding, and adhesive bonding, tackling issues such as metallurgical compatibility, thermal management, and joint integrity.

Through experimental manufacturing trials, material and joints mechanical characterization, numerical modeling and advanced experimental characterization of dissimilar joints and structures, this special issue fosters scientific discourse and practical insights essential for developing efficient and sustainable dissimilar metal joining techniques. It serves as a platform to bridge theoretical understanding with real-world applications, facilitating the advancement of manufacturing technologies and materials science.

Dr. Daniel F.O. Braga
Dr. Sérgio Tavares
Guest Editors

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Keywords

  • dissimilar joining
  • welding
  • intermetallics
  • bonding mechanisms
  • structural integrity
  • fatigue
  • fracture
  • corrosion

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Published Papers (1 paper)

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Research

23 pages, 3805 KB  
Article
Sustainable Drilling Strategies for Rivet Hole Formation in Nickel-Based Alloys for Aeronautical Applications
by José Manuel Sáenz de Pipaón, Amabel García-Domínguez, Juan Claver and Eva María Rubio
J. Manuf. Mater. Process. 2025, 9(12), 389; https://doi.org/10.3390/jmmp9120389 - 25 Nov 2025
Abstract
The formation of rivet holes is a critical step in aeronautical assembly, as hole quality directly influences the fatigue resistance and structural reliability of riveted joints. Nickel-based alloys, such as Inconel 625, present additional challenges due to their poor machinability and the stringent [...] Read more.
The formation of rivet holes is a critical step in aeronautical assembly, as hole quality directly influences the fatigue resistance and structural reliability of riveted joints. Nickel-based alloys, such as Inconel 625, present additional challenges due to their poor machinability and the stringent surface integrity requirements imposed by the aerospace sector. This study investigates innovative and sustainable drilling strategies for rivet hole preparation, focusing on the comparative performance of two environmentally friendly cooling and lubrication methods: minimum quantity lubrication with an eco-friendly fluid (MQL-Eco) and cold compressed air (CCA). A comprehensive experimental campaign was carried out to analyze the combined effects of spindle speed, S, feed rate, f, and cooling method, R, on hole surface roughness parameters (Ra and Rz). These values are measured inside the drilled hole using optical scanner 3D equipment. Statistical tools, including analysis of variance (ANOVA) and response surface methodology (RSM), were employed to identify the most significant factors and optimize cutting conditions. The results reveal that the interaction between spindle speed and coolant type is the dominant contributor to surface roughness variability, with MQL-Eco consistently achieving values within the aeronautical standard range (Ra = 0.8–1.6 µm), and the coolant factor is the second cause of variability in both roughness Ra and Rz. Moreover, correlations between roughness parameters and tool wear confirm the relevance of sustainable cooling methods in extending tool life while maintaining compliance with aerospace quality requirements. The findings demonstrate that innovative eco-friendly drilling approaches can effectively replace conventional lubrication, offering a viable pathway towards greener manufacturing practices in metal forming and joining technologies. Full article
(This article belongs to the Special Issue Advances in Dissimilar Metal Joining and Welding, 2nd Edition)
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