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Welding and Joining Technologies for Advanced Structural Alloys and Multifunctional Materials

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 20 March 2026 | Viewed by 603

Special Issue Editor


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Guest Editor
Department of Materials System Engineering, Pukyong National University, Busan, Republic of Korea
Interests: welding and additive manufacturing of metallic materials; hot cracking

Special Issue Information

Dear Colleagues,

We are delighted to introduce this Special Issue, titled “Welding and Joining Technologies for Advanced Structural Alloys and Multifunctional Materials.”

The growing demand for high-performance materials in energy generation, storage, and conversion systems requires innovative approaches to welding, joining, and additive manufacturing. This Special Issue focuses on the welding and joining of advanced structural alloys, composites, and multifunctional materials, as well as on welding-based additive manufacturing, which has emerged as a key enabling technology for next-generation energy devices.

Topics of interest include advanced welding and joining methods for high-performance alloys and composites, welding-enabled additive manufacturing of complex energy-related components, and the critical issue of hot cracking in these materials. We particularly welcome contributions on new evaluation techniques for cracking susceptibility and computational modeling that shed light on microstructural evolution and defect formation during welding and additive processes.

We invite researchers and practitioners to submit original research articles and review papers that advance the science and engineering of welding, joining, and additive manufacturing for energy-related structural materials.

We look forward to your contributions to this Special Issue.

Prof. Dr. Eun−Joon Chun
Guest Editor

Manuscript Submission Information

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Keywords

  • advanced welding and related additive manufacturing processes
  • advanced structural alloys and composite materials
  • hot cracking phenomena and its testing procedures
  • modeling and simulations techniques

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Published Papers (1 paper)

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Research

16 pages, 11074 KB  
Article
Investigation of the Phosphorus Effect on Solidification Cracking in Cu–Steel Single-Mode Fiber-Laser Welds for Reliable Li-Ion Battery Busbar Assembly
by Ye-Ji Yoo, Jeong-Hoi Koo and Eun-Joon Chun
Materials 2025, 18(24), 5585; https://doi.org/10.3390/ma18245585 - 12 Dec 2025
Viewed by 443
Abstract
Solidification cracking is a critical defect in Cu–steel dissimilar laser welding for cylindrical lithium-ion battery busbar assembly, yet the metallurgical role of phosphorus (P) in crack formation has not been quantitatively established. In this study, the influence of phosphorus in the coating layer [...] Read more.
Solidification cracking is a critical defect in Cu–steel dissimilar laser welding for cylindrical lithium-ion battery busbar assembly, yet the metallurgical role of phosphorus (P) in crack formation has not been quantitatively established. In this study, the influence of phosphorus in the coating layer on weld solidification behavior was clarified by preparing Cu substrates with four different coating conditions—Ni–P-coated Cu (10 and 50 μm) and pure Ni-coated Cu (10 and 50 μm)—and performing high-speed single-mode fiber-laser welding under identical heat-input conditions. Shear-tensile testing, EPMA-based microstructural analysis, and Thermo-Calc solidification calculations were combined to correlate P segregation with solidification cracking susceptibility. The Ni–P 10 μm coating generated severe solidification cracking compared with the pure Ni 50 μm coating, which was attributed to excessive P enrichment in the terminal liquid phase (up to 8.8 mass%). This enrichment significantly expanded the mushy-zone width to approximately 869 K, yielding a highly solidification crack-susceptible fusion zone. In contrast, 50 μm pure Ni coatings produced narrow mushy-zone widths (200–400 K) and extremely low residual P levels (~0.1 mass%), resulting in fully crack-free microstructures. The 50 μm Ni coating exhibited the highest shear-tensile strength and largest rupture displacement among all conditions, confirming that suppression of P segregation directly improves both structural integrity and mechanical performance. Overall, this study demonstrates that phosphorus enrichment critically governs the solidification-cracking susceptibility of Cu–steel dissimilar welds by widening the solidification temperature range. Eliminating P from the coating layer and applying an adequately thick pure Ni coating constitute highly effective strategies for achieving crack-free, mechanically robust welds in lithium-ion battery busbar manufacturing. Full article
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