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Metal Forming and Joining
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Metal Forming and Joining

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: closed (30 November 2021) | Viewed by 20575

Special Issue Editor

Prof. Dr. Chris Valentin Nielsen

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Technical University of Denmark, DK-2800 Kongens Lyngby, Denmark
Interests: metal forming and joining

Special Issue Information

Dear Colleagues,

Metal forming is an efficient manufacturing method resulting in parts of high quality. Those parts will most often be joined to other parts, which are either formed or manufactured by other processes. The efficiency and quality of the joining process are highly influential to the final product. In this Special Issue of JMMP, current research findings will be reported within the following three main areas:

  • Metal forming of parts prepared for subsequent joining.

Examples include the forming of specific geometric features for subsequent joining, forming with high geometrical or dimensional accuracy necessary for subsequent joining, and the creation of beneficial surface conditions by forming for subsequent joining.

  • Joining processes suitable for joining assemblies involving one or more formed parts.

Various joining methods fall under this topic. Examples include resistance welding of formed sheet parts of, for example, advanced high strength steels or ultra-high strength steels, TIG welding of stainless tubular parts or tanks, and ultrasonic welding of dissimilar materials.

  • Hybrid processes involving both metal forming and joining.

This may include joining by plastic deformation, simultaneous forming of multiple materials to form hybrid components, and joining by combining welding/additive manufacturing with forming.

Within these three areas we welcome a wide range of contributions on topics such as the following:
  • Sheet metal forming, bulk metal forming, and tube forming, as well as their combinations.
  • Joining by plastic deformation, e.g., riveting, clinching, cold welding, and joining by forming.
  • Welding, e.g., arc welding, resistance welding, friction welding, friction stir welding, and ultrasonic welding.
  • The combination of product and process design facilitating forming and joining.
  • Tool design facilitating forming and joining.
  • Joining of dissimilar materials involving one or more formed part(s).

Prof. Dr. Chris Valentin Nielsen
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. Journal of Manufacturing and Materials Processing 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 1800 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

  • metal forming
  • joining
  • plastic deformation
  • welding
  • dissimilar materials

Published Papers (8 papers)

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11 pages, 3186 KiB  
Communication
Influence of the Production Process on the Binding Mechanism of Clinched Aluminum Steel Mixed Compounds
by Jan Kalich and Uwe Füssel
J. Manuf. Mater. Process. 2021, 5(4), 105; https://doi.org/10.3390/jmmp5040105 - 30 Sep 2021
Cited by 6 | Viewed by 1649
Abstract
The multi-material design and the adaptability of a modern process chain require joining connections with specifically adjustable mechanical, thermal, chemical, or electrical properties. Previous considerations primarily focused on the mechanical properties. The multitude of possible combinations of requirements, materials, and component- and joining-geometry [...] Read more.
The multi-material design and the adaptability of a modern process chain require joining connections with specifically adjustable mechanical, thermal, chemical, or electrical properties. Previous considerations primarily focused on the mechanical properties. The multitude of possible combinations of requirements, materials, and component- and joining-geometry makes an empirical determination of these joining properties for the clinching process impossible. Based on the established and empirical procedure, there is currently no model that takes into account all questions of joinability—i.e., the materials (suitability for joining), design (security of joining), and production (joining possibility)—that allows a calculation of the properties that can be achieved. It is therefore necessary to describe the physical properties of the joint as a function of the three binding mechanisms—form closure, force closure, and material closure—in relation to the application. This approach illustrates the relationships along the causal chain “joint requirement-binding mechanism-joining parameters” and improves the adaptability of the mechanical joining technology. Geometrical properties of clinch connections of the combination of aluminum and steel are compared in a metallographic cross-section. The mechanical stress state of the rotationally symmetrical clinch points is qualified with a torsion test and by measuring the electrical resistance in the base material, in the clinch joint, and during the production cycle (after clinching, before precipitation hardening and after precipitation hardening). Full article
(This article belongs to the Special Issue Metal Forming and Joining)
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26 pages, 14459 KiB  
Article
Strain Induced Surface Change in Sheet Metal Forming: Numerical Prediction, Influence on Friction and Tool Wear
by Yutian Wu, Viktor Recklin and Peter Groche
J. Manuf. Mater. Process. 2021, 5(2), 29; https://doi.org/10.3390/jmmp5020029 - 30 Mar 2021
Cited by 14 | Viewed by 2901
Abstract
In sheet metal forming, free deformation of the sheet takes place frequently without contact with forming tools. The pre-straining resulting from the free deformation leads to a surface roughening of the sheet metal. It is assumed that the roughening has an influence on [...] Read more.
In sheet metal forming, free deformation of the sheet takes place frequently without contact with forming tools. The pre-straining resulting from the free deformation leads to a surface roughening of the sheet metal. It is assumed that the roughening has an influence on friction and wear behavior of the following forming process as well as the painting quality after the manufacturing. In this paper, a numerical prediction based on a polycrystalline model is first proposed to predict the effect of surface roughing based on the material data of the as-received state of the sheet metal. Different states of strain are analyzed and the numerical result is validated through experimental evaluation. Besides the numerical prediction, the friction behavior after pre-straining is evaluated in strip drawing tests and the coefficient of friction (COF) is calculated. For interpretation of the measured COF, the surface roughness after the friction test and the surface image are evaluated by a transparent toolset. It is shown that the surface transformation as a result of pre-straining has a negative influence on the lubricating effect of the sheet metal and degrades the friction behavior. Finally, the influence of the strain-induced surface roughening on wear is discussed based on wear testing in strip drawing test with draw bead geometry. Full article
(This article belongs to the Special Issue Metal Forming and Joining)
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20 pages, 26949 KiB  
Article
Experimental Study on Joining by Forming of HCT590X + Z and EN-AW 6014 Sheets Using Cold Extruded Pin Structures
by David Römisch, Martin Kraus and Marion Merklein
J. Manuf. Mater. Process. 2021, 5(1), 25; https://doi.org/10.3390/jmmp5010025 - 17 Mar 2021
Cited by 11 | Viewed by 2705
Abstract
Due to stricter emission targets in the mobility sector and the resulting trend towards lightweight construction in order to reduce weight and consequently emissions, multi-material systems that allow a material to be placed in the right quantity and in the right place are [...] Read more.
Due to stricter emission targets in the mobility sector and the resulting trend towards lightweight construction in order to reduce weight and consequently emissions, multi-material systems that allow a material to be placed in the right quantity and in the right place are becoming increasingly important. One major challenge that is holding back the rapid and widespread use of multi-material systems is the lack of adequate joining processes that are suitable for joining dissimilar materials. Joining processes without auxiliary elements have the advantage of a reduced assembly effort and no additional added weight. Conventional joining processes without auxiliary elements, such as welding, clinching, or the use of adhesives, reach their limits due to different mechanical properties and chemical incompatibilities. A process with potential in the field of joining dissimilar materials is joining without an auxiliary element using pin structures. However, current pin manufacturing processes are mostly time-consuming or can only be integrated barely into existing industrial manufacturing processes due to their specific properties. For this reason, the present work investigates the production of single- and multi-pin structures from high-strength dual-phase steel HCT590X + Z (DP600, t0 = 1.5 mm) by cold extrusion directly out of the sheet metal. These structures are subsequently joined with an aluminium sheet (EN AW-6014-T4, t0 = 1.5 mm) by direct pin pressing. For a quantitative evaluation of the joint quality, tensile shear tests are carried out and the influence of different pin heights, pin number, and pin arrangements, as well as different joining strategies on the joint strength is experimentally evaluated. It is proven that a single pin structure with a diameter of 1.5 mm and an average height of 1.86 mm achieves a maximum tensile shear force of 1025 N. The results reveal that the formation of a form-fit during direct pin pressing is essential for the joint strength. By increasing the number of pins, a linear increase in force could be demonstrated, which is independent of the arrangement of the pin structures. Full article
(This article belongs to the Special Issue Metal Forming and Joining)
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25 pages, 41821 KiB  
Article
Shielded Active Gas Forge Welding of an L80 Steel in a Small Scale Shielded Active Gas Forge Welding Machine
by Vinothkumar Palanisamy, Jan Ketil Solberg and Per Thomas Moe
J. Manuf. Mater. Process. 2021, 5(1), 16; https://doi.org/10.3390/jmmp5010016 - 08 Feb 2021
Cited by 3 | Viewed by 2805 | Correction
Abstract
The Shielded Active Gas Forge Welding (SAG-FW) method is a solid-state welding technique in which the mating surfaces are heated by induction heating or direct electrical heating before being forged together to form a weld. In this article, an API 5CT L80 grade [...] Read more.
The Shielded Active Gas Forge Welding (SAG-FW) method is a solid-state welding technique in which the mating surfaces are heated by induction heating or direct electrical heating before being forged together to form a weld. In this article, an API 5CT L80 grade carbon steel alloy has been welded using the SAG-FW method. A small-scale forge welding machine has been used to join miniature pipes extracted from a large pipe wall. The welding was performed at three different forging temperatures, i.e., 1300 °C, 1150 °C and 950 °C, in some cases followed by one or two post weld heat treatment cycles. In order to qualify the welds, mechanical and corrosion testing was performed on miniature samples extracted from the welded pipes. In addition, the microstructure of the welds was analysed, and electron probe microanalysis was carried out to control that no oxide film had formed along the weld line. Based on the complete set of experimental results, promising parameters for SAG-FW welding of the API 5CT L80 grade steel are suggested. The most promising procedure includes forging at relative high temperature (1150 °C) followed by rapid cooling and a short temper. This procedure was found to give a weld zone microstructure dominated by tempered martensite with promising mechanical and corrosion properties. The investigation confirmed that small scale forge welding testing is a useful tool in the development of welding parameters for full size SAG-FW welding. Full article
(This article belongs to the Special Issue Metal Forming and Joining)
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13 pages, 5422 KiB  
Article
Numerical and Experimental Study of AlSi Coating Effect on Nugget Size Growth in Resistance Spot Welding of Hot-Stamped Boron Steels
by Ali Afzal, Mohsen Hamedi and Chris Valentin Nielsen
J. Manuf. Mater. Process. 2021, 5(1), 10; https://doi.org/10.3390/jmmp5010010 - 15 Jan 2021
Cited by 4 | Viewed by 2271
Abstract
In recent years, increasing automotive safety by improving crashworthiness has been a focal point in the automotive industry, employing high-strength steel such as press hardenable steel (PHS). In addition to the improved strength of individual parts in the body of the vehicle, the [...] Read more.
In recent years, increasing automotive safety by improving crashworthiness has been a focal point in the automotive industry, employing high-strength steel such as press hardenable steel (PHS). In addition to the improved strength of individual parts in the body of the vehicle, the strength of the resistance-spot-welded joints of these parts is highly important to obtain a safe structure. In general, dimensions of weld nuggets are regarded as one of the criteria for the quality of spot-welded joints. In the presented research, a three-dimensional axisymmetric finite element model is developed to predict the nugget formation in resistance spot welding (RSW) of two types of PHS: the uncoated and AlSi-coated 1.8 mm boron steel after hot stamping. A fully coupled electro-thermo-mechanical analysis was conducted using the commercial software package Abaqus. The FE predicted weld nugget development is compared with experimental results. The computed weld nugget sizes show good agreement with experimental values. Full article
(This article belongs to the Special Issue Metal Forming and Joining)
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19 pages, 3220 KiB  
Article
Experimental and Numerical Assessment of the Hot Sheet Formability of Martensitic Stainless Steels
by Peter Birnbaum, Enrique Meza-García, Pierre Landgraf, Thomas Grund, Thomas Lampke and Verena Kräusel
J. Manuf. Mater. Process. 2020, 4(4), 122; https://doi.org/10.3390/jmmp4040122 - 16 Dec 2020
Cited by 3 | Viewed by 2005
Abstract
Hot formed sheet components made of Martensitic Stainless Steels (MSS) can achieve ultra-high strengths in combination with very high corrosion resistance. This enables to manufacture complex lightweight sheet components with longer lifespan. Nevertheless, the hot formability of MSS sheets has not been accurately [...] Read more.
Hot formed sheet components made of Martensitic Stainless Steels (MSS) can achieve ultra-high strengths in combination with very high corrosion resistance. This enables to manufacture complex lightweight sheet components with longer lifespan. Nevertheless, the hot formability of MSS sheets has not been accurately evaluated considering high temperatures and complex stress and strain states. In this work, the hot sheet formability of three MSS alloys under thermomechanical process conditions was investigated. Initially, mechanical properties of this sheet material were determined by uniaxial tensile test. Finite Element Method (FEM) simulation of a hot deep drawing process was performed under consideration of thermo physical calculated material models using the software JMatPro® and Simufact Forming® 15.0. The resulting strains and cooling rates developed locally in the work piece during the forming process were estimated. The numerical results were validated experimentally. Round cups were manufactured by hot deep drawing process. The resulting maximum drawing depth and hardness were measured. In general, all three alloys developed very good formability at forming temperatures between 700 and 900 °C and increased hardness values. However, they are highly susceptible to chemical composition, austenitization temperature, dwell time, and flange gap. A statistic approach is given to explain the correlation between hardness and its influencing factors. Full article
(This article belongs to the Special Issue Metal Forming and Joining)
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12 pages, 5944 KiB  
Article
Hybrid Additive Manufacturing of Collector Coins
by João P. M. Pragana, Stephan Rosenthal, Ivo M. F. Bragança, Carlos M. A. Silva, A. Erman Tekkaya and Paulo A. F. Martins
J. Manuf. Mater. Process. 2020, 4(4), 115; https://doi.org/10.3390/jmmp4040115 - 09 Dec 2020
Cited by 7 | Viewed by 3374
Abstract
The objective of this paper is to present a new hybrid additive manufacturing route for fabricating collector coins with complex, intricate contoured holes. The new manufacturing route combines metal deposition by additive manufacturing with metal cutting and forming, and its application is illustrated [...] Read more.
The objective of this paper is to present a new hybrid additive manufacturing route for fabricating collector coins with complex, intricate contoured holes. The new manufacturing route combines metal deposition by additive manufacturing with metal cutting and forming, and its application is illustrated with an example consisting of a prototype coin made from stainless steel AISI 316L. Experimentation and finite element analysis of the coin minting operation with the in-house computer program i-form show that the blanks produced by additive manufacturing and metal cutting can withstand the high compressive pressures that are attained during the embossing and impressing of lettering and other reliefs on the coin surfaces. The presentation allows concluding that hybrid additive manufacturing opens the way to the production of innovative collector coins with geometric features that are radically different from those that are currently available in the market. Full article
(This article belongs to the Special Issue Metal Forming and Joining)
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2 pages, 172 KiB  
Correction
Correction: Palanisamy et al. Shielded Active Gas Forge Welding of an L80 Steel in a Small Scale Shielded Active Gas Forge Welding Machine. J. Manuf. Mater. Process. 2021, 5, 16
by Vinothkumar Palanisamy, Jan Ketil Solberg and Per Thomas Moe
J. Manuf. Mater. Process. 2021, 5(3), 79; https://doi.org/10.3390/jmmp5030079 - 27 Jul 2021
Viewed by 1572
Abstract
The authors wish to make the following corrections to this paper [...] Full article
(This article belongs to the Special Issue Metal Forming and Joining)
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