Friction Stir Welding and Processing of Dissimilar Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Welding and Joining".

Deadline for manuscript submissions: 31 October 2025 | Viewed by 503

Special Issue Editor


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Guest Editor
Mechanical Engineering Department, University of South Africa, Florida, Gauteng 1709, South Africa
Interests: dissimilar welding; processing of dissimilar materials

Special Issue Information

Dear Colleagues,

Metal-based structures are produced using various joining techniques. This includes fusion- and friction-based techniques. The latter are the most preferred since they do not produce fumes during their operation and are categorized as green technology. They are classified into two major classes, i.e., friction welding and friction stir welding. These techniques are fairly new; hence, their industrial application is still limited. This suggests that there are more aspects related to this type of joining that still need to be explored. It should be noted that there is a lot that has been done in advancing this technique. However, the literature is dominated by the use of this technique to join or process similar materials. This Special Issue seeks submissions that deal with the joining and processing of dissimilar materials.

This Special Issue will consider original papers covering the following areas:

  • Repair of dissimilar joints using friction-based techniques;
  • Experimental and numerical modeling of friction-based techniques; 
  • Effects of processing parameters on different properties of dissimilar joints;
  • Correlation between microstructure, tribological, and mechanical properties of dissimilar joints;
  • Optimization of fabrication parameters for friction-based techniques;
  • Parameters affecting mechanical and tribological properties of structures manufactured using dissimilar materials.

Dr. Msomi Velaphi
Guest Editor

Manuscript Submission Information

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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. Metals is an international peer-reviewed open access monthly 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

  • dissimilar welding
  • processing of dissimilar materials
  • influence of welding parameters on dissimilar materials
  • optimization of welding parameters for dissimilar materials
  • repair of joints using friction stir processing

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Published Papers (1 paper)

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Research

17 pages, 3064 KiB  
Article
Effect of Elastic Strain Energy on Dynamic Recrystallization During Friction Stir Welding of Dissimilar Al/Mg Alloys
by Faliang He, Lei Shi and Chuansong Wu
Metals 2025, 15(6), 577; https://doi.org/10.3390/met15060577 - 23 May 2025
Abstract
Dynamic recrystallization (DRX) is a critical microstructural evolution mechanism in friction stir welding (FSW) of metallic materials, directly determining the mechanical properties and corrosion resistance of weld joints. In the field of DRX simulation, conventional models primarily consider intragranular dislocation strain energy as [...] Read more.
Dynamic recrystallization (DRX) is a critical microstructural evolution mechanism in friction stir welding (FSW) of metallic materials, directly determining the mechanical properties and corrosion resistance of weld joints. In the field of DRX simulation, conventional models primarily consider intragranular dislocation strain energy as the driving force for recrystallization, while neglecting the elastic strain energy generated by coordinated deformation in polycrystalline materials. This study presents an improved DRX modeling framework that incorporates the multiphase-field method to systematically investigate the role of elastic strain energy in microstructural evolution during FSW of Al/Mg dissimilar materials. The results demonstrate that elastic strain energy can modulate nucleation and the growth of recrystallized grains during microstructural evolution, resulting in post-weld average grain size increases of 0.8% on the Al side and 2.1% on the Mg side in the FSW nugget zone. This research provides new insights into multi-energy coupling mechanisms in DRX simulation and offers theoretical guidance for process optimization in dissimilar material welding. Full article
(This article belongs to the Special Issue Friction Stir Welding and Processing of Dissimilar Materials)
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