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Advanced Materials Joining and Manufacturing Techniques
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Advanced Materials Joining and Manufacturing Techniques

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

Deadline for manuscript submissions: closed (20 April 2025) | Viewed by 5265

Special Issue Editors

Dr. Michael Benoit

E-Mail Website
Guest Editor
Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, ON, Canada
Interests: materials processing (processing, structure, properties relationships); welding and joining; additive manufacturing; alloy development (solidification cracking)
Dr. Xiaoye Zhao

E-Mail Website
Guest Editor
Centre for Advanced Materials Joining, Department of Mechanical & Mechatronics Engineering, University of Waterloo, 200 University Avenue West, Waterloo, ON N2L 3G1, Canada
Interests: welding and joining; laser welding; laser brazing; laser surface engineering; additive manufacturing

Special Issue Information

Dear Colleagues,

Materials joining and welding is an essential component of manufacturing technology and is one of the main ways to manufacture parts for a wide range of products from giant structures to micro and nano devices such as pipelines, aircrafts, automobiles, medical devices and microelectronics. With the continuous emergence of engineering materials and applications, various advanced technologies have been developed on a macro and micro scale. For example, weight reduction without compromising any safety and performance criteria with reasonable cost is one priority for automotive industry which enables the development of dissimilar materials joining. Brazing technologies have attracted interest in recent years due to their ability to reduce some defects that occur during fusion welding of zinc coated steel. Joining related to shape memory alloy or high-entropy alloy have been developed and evaluated. Advances in welding and joining help to achieve unique joint properties, join complex structures or materials, reduce costs, improve productivity and quality, and select suitable material for new products.

This Special Issue “Advanced Materials Joining and Manufacturing Techniques” aims to summarize recent advances in all aspects of welding and joining, including microstructure, mechanical properties, corrosion performance, and other properties. Studies on the material characterization of the joint and technique development are of interest. The main content of this Special Issue includes, but is not limited to, arc welding, laser welding, friction stir welding, micro joining, additive manufacturing (deposition with wire or powder), and other relevant advanced techniques.

Dr. Michael Benoit
Dr. Xiaoye Zhao
Guest Editors

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. Materials 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 2600 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

  • fusion welding
  • brazing
  • solid-state welding
  • additive manufacturing
  • dissimilar materials joining
  • micro joining

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Published Papers (5 papers)

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Research

14 pages, 5039 KiB  
Article
Study on Mechanical Properties and Microstructure of 2024 Aluminum Alloy Cross-Welded Joint by Friction Stir Welding
by Yanning Guo and Wenbo Sun
Materials 2025, 18(10), 2223; https://doi.org/10.3390/ma18102223 - 12 May 2025
Viewed by 225
Abstract
The integral welded panel represents a highly promising aircraft structural component, owing to its lightweight design and reduced connector requirements. However, the complexity of its welded structure results in the formation of cross-welded joints. This study systematically investigated the mechanical properties of the [...] Read more.
The integral welded panel represents a highly promising aircraft structural component, owing to its lightweight design and reduced connector requirements. However, the complexity of its welded structure results in the formation of cross-welded joints. This study systematically investigated the mechanical properties of the cross-welded joints through tensile tests across different welded regions, which were complemented by fracture morphology examination via scanning electron microscopy (SEM). The residual stress distribution was characterized using X-ray diffraction, while electron backscatter diffraction (EBSD) analysis was used to elucidate the relationship between residual stress and microstructure. Key findings revealed that the cross-welded zone exhibited lower yield strength and ductility than the single-welded zone, and the advancing heat-affected zone demonstrated superior tensile properties relative to the retreating side. Residual stress analysis showed that the cross-welded joint lacked the “double peak” profile characteristic and displayed lower maximum residual stress than the single-welded joint. EBSD analysis indicated significant grain elongation in the cross-welded zone due to mechanical forces during the welding process, resulting in higher dislocation density and deformation, corresponding with elevated residual stress levels. Full article
(This article belongs to the Special Issue Advanced Materials Joining and Manufacturing Techniques)
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23 pages, 17563 KiB  
Article
Creep Resistance and Microstructure Evolution in P23/P91 Welds
by Vlastimil Vodárek, Jan Holešinský, Zdeněk Kuboň, Renáta Palupčíková, Petra Váňová and Jitka Malcharcziková
Materials 2025, 18(1), 194; https://doi.org/10.3390/ma18010194 - 5 Jan 2025
Viewed by 664
Abstract
This paper summarizes the results of investigations into heterogeneous P23/P91 welds after long-term creep exposure at temperatures of 500, 550 and 600 °C. Two variants of welds were studied: In Weld A, the filler material corresponded to P91 steel, while in Weld B, [...] Read more.
This paper summarizes the results of investigations into heterogeneous P23/P91 welds after long-term creep exposure at temperatures of 500, 550 and 600 °C. Two variants of welds were studied: In Weld A, the filler material corresponded to P91 steel, while in Weld B, the chemical composition of the consumable material matched P23 steel. The creep rupture strength values of Weld A exceeded those of Weld B at all testing temperatures. Most failures in the cross-weld samples occurred in the partially decarburized zones of P23 or WM23 steel. The results of the investigations on the minor phases were in good agreement with kinetic simulations that considered a 0.1 mm fusion zone. Microstructural studies proved that carburization occurred in the P23/P91 weld fusion zones. The partial decarburization of P23 steel or WM23 was accompanied by the dissolution of M7C3 and M23C6 particles, and detailed studies revealed the precipitation of the Fe2 (W, Mo) Laves phase in decarburized areas. Thermodynamic simulations proved that the appearance of this phase in partially decarburized P23 steel or WM23 is related to a reduction in the carbon content in these areas. According to the results of creep tests, the EBSD investigations revealed a better microstructural stability of the partially decarburized P23 steel in Weld A. Full article
(This article belongs to the Special Issue Advanced Materials Joining and Manufacturing Techniques)
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17 pages, 10666 KiB  
Article
Prediction of Mechanical Properties and Fracture Behavior of TC17 Linear Friction Welded Joint Based on Finite Element Simulation
by Xuan Xiao, Yue Mao and Li Fu
Materials 2025, 18(1), 128; https://doi.org/10.3390/ma18010128 - 31 Dec 2024
Viewed by 676
Abstract
TC17 titanium alloy is widely used in the aviation industry for dual-performance blades, and linear friction welding (LFW) is a key technology for its manufacturing and repair. However, accurate evaluation of the mechanical properties of TC17−LFW joints and research on their joint fracture [...] Read more.
TC17 titanium alloy is widely used in the aviation industry for dual-performance blades, and linear friction welding (LFW) is a key technology for its manufacturing and repair. However, accurate evaluation of the mechanical properties of TC17−LFW joints and research on their joint fracture behavior are still not clear. Therefore, this paper used the finite element numerical simulation method (FEM) to investigate the mechanical behavior of the TC17−LFW joint with a complex micro−structure during the tensile processing, and predicted its mechanical properties and fracture behavior. The results indicate that the simulated elastic modulus of the joint is 108.5 GPa, the yield strength is 1023.2 MPa, the tensile strength is 1067.5 MPa, and the elongation is 1.98%. The deviations from measured results between simulated results are less than 2%. The stress and strain field studies during the processing show that the material located at the upper and lower edges of the joint in the WZ experiences stress and strain concentration, followed by the extending of the stress and strain concentration zone toward the center of the WZ. And finally, the strain concentration zone covered the entire WZ. The fracture behavior studies show that the material necking occurs in the TMAZ of TC17(α + β) and WZ, while cracks first appear in the WZ. Subsequently, joint cracks propagate along the TC17(α + β) side of the WZ until fracture occurs. There are obvious tearing edges formed by the partial tearing of the WZ structure in the simulated fracture surface, and there are fracture surfaces with different height differences at the center of the joint crack, indicating that the joint has mixed fracture characteristics. Full article
(This article belongs to the Special Issue Advanced Materials Joining and Manufacturing Techniques)
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13 pages, 3313 KiB  
Article
A Deep Learning Model for Estimating the Quality of Bimetallic Tracks Obtained by Laser Powder-Directed Energy Deposition
by Vincent Wong, Alberta Aversa and Alessandro Roger Rodrigues
Materials 2024, 17(22), 5653; https://doi.org/10.3390/ma17225653 - 19 Nov 2024
Viewed by 1493
Abstract
During the fabrication of Inconel 718–AISI 316L bimetallic components via laser powder-directed energy deposition, understanding the relationships between processes, microstructures, and material properties is crucial to obtaining high-quality parts. Physical–chemical properties, cooling rates, and thermal expansion coefficients of each material may affect the [...] Read more.
During the fabrication of Inconel 718–AISI 316L bimetallic components via laser powder-directed energy deposition, understanding the relationships between processes, microstructures, and material properties is crucial to obtaining high-quality parts. Physical–chemical properties, cooling rates, and thermal expansion coefficients of each material may affect the microstructure of parts, generating segregations and cracks. This paper analyzes how the process parameters affect the dimensions, chemical composition, and microhardness of bimetallic tracks. We created a dataset that included laser power, powder feed rate, material, skeletal density, dimensional features, chemical composition, and microhardness. Then, a deep learning methodology using a multilayer perceptron was used to estimate the relationship between these factors. The architecture comprised four inputs in the input layer and five hidden layers with 20, 40, 30, 30, and 30 neurons, respectively. This architecture was used to estimate the dimensional features, chemical composition, and microhardness. The model precision was evaluated using the determination coefficient (R2) and the mean absolute error (MAE) function. Lastly, we used a random forest classifier to select the bead quality from the optimal process parameters. The results showed a significant decrease in training loss and validation loss between 50 and 100 epochs. This decreasing trend continued until 350 epochs. This paper contributes to understanding the relationships between process–structure properties in the bimetallic tracks of Inconel 718 and AISI 316L. Full article
(This article belongs to the Special Issue Advanced Materials Joining and Manufacturing Techniques)
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23 pages, 28801 KiB  
Article
Effects of Heat Input and Intertrack Overlap on the Microstructure and Properties of Inconel 686 Weld Overlays
by Seyedmohammad Tabaie, Zahra Khodamoradi, Trevor Greene and Michael J. Benoit
Materials 2024, 17(13), 3315; https://doi.org/10.3390/ma17133315 - 4 Jul 2024
Viewed by 1308
Abstract
The objective of this study was to investigate how weld overlays with nickel superalloys are important for the integrity, due the high temperatures and corrosive environments that can be experienced in mineral processing environments, of mining and processing equipment. The Ni-Cr-Mo superalloy Inconel [...] Read more.
The objective of this study was to investigate how weld overlays with nickel superalloys are important for the integrity, due the high temperatures and corrosive environments that can be experienced in mineral processing environments, of mining and processing equipment. The Ni-Cr-Mo superalloy Inconel 686 overlays are fabricated through automatic gas metal arc welding with variations in arc voltage and travel speed (i.e., heat input), and they have overlap between adjacent weld tracks for applications in the mining and minerals sector. The impact of variations in the process parameters and the size of the weld overlapping on the dilution, solidification morphology, microsegregation, and microhardness were investigated. Both geometric and chemical composition definitions were used to quantify the extent of the weld dilution. Subsequently, the weld geometry and dilution were correlated with the solidification microstructure and phase transformations. The maximum dilutions were measured to be 13.63% (1/2 overlap, 5.96 kJ·cm−1) and 15.39% (1/3 overlap, 4.77 kJ·cm−1), which shows that less of an overlap increases the dilution level. Scanning electron microscopy and chemical composition analysis revealed that an increase in weld heat input and dilution level led to higher levels of microsegregation for Mo and Cr, as well as the volume fraction of Mo- and Cr-rich phases in the interdendritic/intercellular regions in the overlay layer. Analysis of the weld overlays in the current study revealed strong and unprecedented connections between the weld overlay process conditions, the resultant metallurgy (i.e., dendrite arm spacing, microsegregation, and phase formation), and the hardness of the overlay. It was concluded that the optimal weld overlays in the processing window studied in this investigation were fabricated at mid-level heat inputs (i.e., 4–5 kJ·cm−1) and a 1/2 track overlap. Full article
(This article belongs to the Special Issue Advanced Materials Joining and Manufacturing Techniques)
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