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Advanced Welding Process Development for Metals and Steels: Numerical Analysis, Process Optimization, and Joint Performance

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

Deadline for manuscript submissions: 20 January 2026 | Viewed by 1649

Special Issue Editors

School of Materials and Physics, China University of Mining and Technology, Xuzhou, China
Interests: additive manufacturing; efficient arc welding; laser cladding; numerical simulation and simulation; arc wire additive manufacturing (WAAM); laser cladding of high-entropy alloys; high-speed arc welding; welding of dissimilar materials; machine learning; numerical simulation analysis

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Guest Editor Assistant
School of Materials Science and Engineering, Jiangsu University, 301 Xuefu Road, Zhenjiang, China
Interests: arc welding; laser beam welding; additive manufacturing; numerical analysis of welding process; advanced material connection methods; plasma welding; laser welding; laser-arc hybrid welding process

Special Issue Information

Dear Colleagues,

The development of advanced welding processes for metals and steels is a critical area of research in materials engineering, driven by the demand for high-performance joints in industries such as aerospace, automotive, and energy. Welding, a fundamental manufacturing technique, joins metallic components by applying heat, pressure, or both, often under complex conditions. Advanced welding processes—such as laser welding, friction stir welding, and hybrid techniques—offer improved precision, efficiency, and mechanical properties, addressing various limitations.

This Special Issue aims to advance the understanding and application of innovative welding technologies in materials engineering. It seeks to explore cutting-edge processes—such as laser welding, friction stir welding, and hybrid methods—focusing on their development for metals and steels. By integrating numerical analysis, this Issue aims to provide insights into heat transfer, material behavior, and stress distribution, facilitating process optimization. Emphasis will be placed on enhancing joint performance, including strength, durability, and resistance to environmental degradation, critical for industries like aerospace, automotive, and energy. This Special Issue invites original research and reviews to bridge theoretical advancements and practical solutions, fostering sustainable manufacturing and supporting the evolution of high-performance materials in modern applications.

In this Special Issue, original research articles and reviews are welcome. Research areas may include (but not limited to) the following: welding processes, numerical analysis, process optimization, and joint performance

We look forward to receiving your contributions.

Dr. Lin Wang
Guest Editor

Dr. Tianqing Li
Guest Editor Assistant

Manuscript Submission Information

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Keywords

  • laser welding
  • arc welding
  • modeling
  • weld
  • joint performance

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Published Papers (3 papers)

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Research

34 pages, 5036 KB  
Article
Multiaxial Fatigue Life Assessment of Large Welded Flange Shafts: A Continuum Damage Mechanics Approach
by Zhiqiang Xu, Chaolong Yang, Feiting Shi, Wenzheng Liu, Na Xu, Zengliang Hu, Chuanqi Li, Ketong Liu, Peng Cao and Di Wang
Materials 2025, 18(24), 5528; https://doi.org/10.3390/ma18245528 - 9 Dec 2025
Viewed by 83
Abstract
This study develops a unified continuum damage mechanics (CDM) model for high-cycle fatigue life prediction of large manually arc-welded flange shafts manufactured from 45Mn steel (quenched and tempered) under combined bending–torsion loading. Fatigue tests revealed consistent crack initiation at the weld toe, with [...] Read more.
This study develops a unified continuum damage mechanics (CDM) model for high-cycle fatigue life prediction of large manually arc-welded flange shafts manufactured from 45Mn steel (quenched and tempered) under combined bending–torsion loading. Fatigue tests revealed consistent crack initiation at the weld toe, with multiaxial loading reducing fatigue life by 35–42% compared to pure bending. The CDM parameters were calibrated against experimental data and implemented through an ABAQUS 2021 UMAT subroutine, achieving prediction errors below 5%—significantly outperforming conventional nominal and hotspot stress methods. For high-cycle fatigue conditions, a simplified CDM model neglecting plastic damage maintained engineering accuracy while improving computational efficiency by 3–5 times. The damage variable D = 0.9 was identified as a universal threshold for accelerated damage progression. These findings provide quantitative basis for multiaxial fatigue design and structural health monitoring of large welded components. Full article
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20 pages, 9797 KB  
Article
The Laser Welding Research of Dissimilar Materials Between AlCoCrFeNi2.1 Eutectic High-Entropy Alloy and GH3030 Nickel-Based Alloy
by Anmin Liu, Ze An, Bin Wang, Hailin Qiao, Keming Chang and Yu Fan
Materials 2025, 18(21), 4970; https://doi.org/10.3390/ma18214970 - 31 Oct 2025
Viewed by 492
Abstract
Dissimilar material welding enables the integration of the superior properties of different materials, thereby achieving optimal structural performance and economic efficiency while meeting specific service requirements. The presence of solid-solution strengthening elements such as Ti, Co, and Al, and trace elements such as [...] Read more.
Dissimilar material welding enables the integration of the superior properties of different materials, thereby achieving optimal structural performance and economic efficiency while meeting specific service requirements. The presence of solid-solution strengthening elements such as Ti, Co, and Al, and trace elements such as P and S, in GH3030 nickel-based superalloy leads to their segregation and the formation of intermetallic compounds in the welded joint, resulting in deterioration of joint performance. High-entropy alloys (HEAs), with their high-entropy effect and delayed diffusion effect working synergistically, can effectively suppress compositional segregation caused by uneven elemental diffusion and the formation of intermetallic compounds at interfaces, thereby improving the quality of welded joints and demonstrating great potential for dissimilar material joining. Therefore, in this study, fiber laser welding was used to effectively join AlCoCrFeNi2.1 eutectic high-entropy alloy and GH3030 nickel-based superalloy, with the expectation to improve welded joint element segregation, suppressing the formation of intermetallic compounds, and enhance the welded joint quality and its performance. The AlCoCrFeNi2.1/GH3030 joint exhibits an average yield strength of 1.31 GPa, which is significantly higher than that of the GH3030/GH3030 joint (1.07 GPa). In addition, the AlCoCrFeNi2.1/GH3030 joint shows a higher average work-hardening exponent of 0.337 compared with 0.30 for the GH3030/GH3030 joint, indicating improved plasticity. The results showed that under appropriate welding process parameters, the hardness of the weld zone, transitioning from the nickel-based superalloy to the eutectic high-entropy alloy, exhibited a stable increasing trend, and the joint exhibits good plasticity, with brittle fracture being unlikely. Full article
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22 pages, 4837 KB  
Article
Predictive Correlation Between Hardness and Tensile Properties of Submerged Arc Welded API X70 Steel
by Ali Lahouel, Sameh Athmani, Amel Sedik, Adel Saoudi, Regis Barille, Lotfi Khezami, Ahlem Guesmi and Mamoun Fellah
Materials 2025, 18(19), 4482; https://doi.org/10.3390/ma18194482 - 25 Sep 2025
Viewed by 850
Abstract
This research investigates the statistical correlation between Vickers hardness and tensile properties of helical submerged arc welded high-strength low-alloy (HSLA) API X70 pipeline steel. Tensile tests were performed on cross-weld joints from 138 pipe specimens. Vickers hardness measurements were also conducted on 138 [...] Read more.
This research investigates the statistical correlation between Vickers hardness and tensile properties of helical submerged arc welded high-strength low-alloy (HSLA) API X70 pipeline steel. Tensile tests were performed on cross-weld joints from 138 pipe specimens. Vickers hardness measurements were also conducted on 138 samples to evaluate the hardness distribution across the base metal, fusion zone, and heat-affected zone. Results show that the fusion zone exhibits the highest hardness, correlating with enhanced tensile strength (R2 = 82%). Linear regression models indicate that base metal hardness significantly influences yield strength (R2 = 71%), while moderate negative correlations exist with elongation (R2 = 54%). These findings suggest that hardness measurements can serve as a non-destructive predictive tool for tensile properties, improving weld quality and mechanical performance. This research provides empirical models that enhance the application of API X70 in critical engineering applications, improving pipeline safety and reliability. Full article
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