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Metals
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New Welding Materials and Green Joint Technology—2nd Edition
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New Welding Materials and Green Joint Technology—2nd Edition

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

Deadline for manuscript submissions: 31 July 2025 | Viewed by 3641

Special Issue Editor

Dr. Fuxiang Wei

E-Mail Website
Guest Editor
School of Materials and Physics, China University of Mining and Technology, Xuzhou 221116, China
Interests: electronic packaging; lead-free solder; green joint technology
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Welding technology, one of the important processes in material engineering, has been widely used in such industrial sectors as aeronautics, astronautics, energy, transportation, chemical industry, weapons, machinery, electronics, and various metal structures. With the constant development of technologies and new materials, great achievements have been made in welding science and technology. New materials and electronic, computer and robotic technologies have been developed, and they provide new opportunities for us to further probe welding technology. However, new materials, components, and devices have higher requirements in welding processes and welding materials. These requirements can promote the innovation of traditional technologies in connecting new or special materials and dissimilar material components the reliability detection and life evaluation of complex welding products, and advance the development of new welding processes and green connection technologies.

This Special Issue welcomes research on innovative green welding materials, new welding processes, and solder processing methods. Studies on additive manufacturing are also within the scope of this Issue.

Dr. Fuxiang Wei
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. 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

  • welding materials
  • welding process
  • electronic packaging
  • connection technologies
  • additive manufacturing

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Related Special Issue

Published Papers (4 papers)

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Research

25 pages, 6917 KiB  
Article
Solid-State Welding of Thin Aluminum Sheets: A Case Study of Friction Stir Welding Alloys 1050 and 5754
by Georgios Patsalias, Konstantinos Sofias and Achilles Vairis
Metals 2025, 15(4), 463; https://doi.org/10.3390/met15040463 - 20 Apr 2025
Viewed by 160
Abstract
This study explores the friction stir welding (FSW) of thin aluminum sheets, focusing on alloys 1050 and 5754. FSW, a solid-state joining technique, offers advantages like minimal deformation and high joint strength, but optimizing welding parameters is crucial for sound welds. In order [...] Read more.
This study explores the friction stir welding (FSW) of thin aluminum sheets, focusing on alloys 1050 and 5754. FSW, a solid-state joining technique, offers advantages like minimal deformation and high joint strength, but optimizing welding parameters is crucial for sound welds. In order to investigate the optimum welding parameters, the Taguchi method was employed, in which key parameters such as rotational and welding speed were optimized to enhance tensile strength and weld quality. The tensile testing of the welded specimens revealed that the optimal combination—1000 RPM rotational speed and 250 mm/min welding speed—produced the highest tensile strength and weld quality. The results highlight the importance of parameter optimization in ensuring strong, stable welds, with rotational speed having the most significant influence. Additionally, excessive rotational speeds were found to weaken welds due to excessive heat input, while a slower welding speed contributed to greater weld stability. Full article
(This article belongs to the Special Issue New Welding Materials and Green Joint Technology—2nd Edition)
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10 pages, 1181 KiB  
Article
Prediction of Weld Geometry in Laser Overlap Welding of Low-Carbon Galvanized Steel
by Kamel Oussaid, Narges Omidi, Abderrazak El Ouafi and Noureddine Barka
Metals 2025, 15(4), 447; https://doi.org/10.3390/met15040447 - 16 Apr 2025
Viewed by 229
Abstract
Accurate prediction of weld bead geometry is critical for optimizing laser overlap welding of low-carbon galvanized steel, as it directly affects joint quality and mechanical performance. Traditional finite element method (FEM)-based models provide reliable predictions but are computationally expensive and impractical for real-time [...] Read more.
Accurate prediction of weld bead geometry is critical for optimizing laser overlap welding of low-carbon galvanized steel, as it directly affects joint quality and mechanical performance. Traditional finite element method (FEM)-based models provide reliable predictions but are computationally expensive and impractical for real-time applications. This study presents an artificial neural network (ANN)-based predictive model trained on a combination of experimental data and validated FEM simulations to estimate key weld characteristics, including depth of penetration (DOP), weld bead width at the surface (WS), and weld bead width at the interface (WI). The ANN model was evaluated using various improved statistical metrics. Results demonstrated a strong correlation between ANN predictions and experimental measurements, with R2 values exceeding 95% for WS and DOP and 92% for WI, and mean errors below 7%. A comparative analysis between ANN, FEM, and experimental data confirmed the model’s reliability across different welding conditions. Additionally, ANN significantly reduced computational time compared to FEM while maintaining high accuracy, making it a practical tool for real-time process optimization. These findings highlight the potential of ANN models as efficient alternatives to conventional simulation techniques in laser overlap welding applications. Future improvements may involve integrating real-time sensor data and deep learning techniques to further enhance predictive performance. Full article
(This article belongs to the Special Issue New Welding Materials and Green Joint Technology—2nd Edition)
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22 pages, 28555 KiB  
Article
Ultrasound-Enhanced Friction Stir Welding of Aluminum Alloy 6082: Advancements in Mechanical Properties and Microstructural Refinement
by Marat Rebrin, Andreas Gester, Dmitrii Ozherelkov, Christiane Wächtler, Toni Sprigode, Martin Mädlow and Guntram Wagner
Metals 2024, 14(11), 1241; https://doi.org/10.3390/met14111241 - 31 Oct 2024
Viewed by 1347
Abstract
This study examines the effects of ultrasound-enhanced friction stir welding (USE-FSW) on the mechanical properties and microstructural characteristics of aluminum alloy AA6082-T6, commonly used in automotive, aerospace, and construction industries. The investigation included tensile and bending tests, as well as detailed microstructural evaluations [...] Read more.
This study examines the effects of ultrasound-enhanced friction stir welding (USE-FSW) on the mechanical properties and microstructural characteristics of aluminum alloy AA6082-T6, commonly used in automotive, aerospace, and construction industries. The investigation included tensile and bending tests, as well as detailed microstructural evaluations using scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and energy-dispersive X-ray spectroscopy (EDS). The results indicate that USE-FSW led to an approximately 26% increase in tensile strength compared to similar samples produced by conventional friction stir welding (CFSW). Additionally, the elongation at break improved by around 52%, indicating better ductility. Flexural strength also showed a notable improvement of over 70%. Microstructural analysis revealed a finer grain structure in the stir zone, contributing to these mechanical enhancements. However, the changes in texture and grain orientation were relatively modest, as shown by EBSD and Kernel Average Misorientation (KAM) analyses. Overall, USE-FSW offers incremental improvements in weld quality and mechanical performance, making it a promising technique for producing joints with slightly enhanced strength and ductility. Full article
(This article belongs to the Special Issue New Welding Materials and Green Joint Technology—2nd Edition)
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Graphical abstract

13 pages, 4900 KiB  
Article
Reliability Simulation of IGBT Module with Different Solders Based on the Finite Element Method
by Haoran Ma, Min Gou, Xingjian Tian, Wei Tan and Hongwei Liang
Metals 2024, 14(10), 1141; https://doi.org/10.3390/met14101141 - 6 Oct 2024
Cited by 3 | Viewed by 1701
Abstract
The interconnecting solder is a key control factor for the reliability of electronic power packaging because it highly affects the junction temperature of insulated-gate bipolar transistor (IGBT) modules and is prone to plasticity, creep, and other failure behaviors under temperature-change environments. In this [...] Read more.
The interconnecting solder is a key control factor for the reliability of electronic power packaging because it highly affects the junction temperature of insulated-gate bipolar transistor (IGBT) modules and is prone to plasticity, creep, and other failure behaviors under temperature-change environments. In this paper, the interconnecting performance and fatigue life of five different kinds of solders such as SAC305, sintered silver, Au80Sn20, sintered copper, and pure In under direct current (DC), power cycle, and electro-thermal coupling complex environments were studied based on electro-thermal multi-physical field coupling finite element simulation method, respectively. Results show that the sintered silver owns the most outstanding thermal reliability and the DC operating junction temperature of the IGBT module after utilizing sintered silver solder is only 90.2 °C, which is nearly 15 °C lower than that of the IGBT module utilizing SAC305 solder. Furthermore, in the power cycle reliability test, the fatigue life of Au80Sn20 solder reaches a maximum of 3.26 × 107 cycles while the life of indium presents only 5.85 × 103 cycles, a difference of nearly four orders of magnitude. Finally, under the complex environment of electro-thermal coupling, the fatigue life of Au80Sn20 solder is also the largest at 1.9 × 106 cycles, while the smallest life of solder becomes SAC305 solder at 4.44 × 102 cycles. The results of this paper can provide a theoretical basis for solder selection and life prediction of the IGBT module, which is of great significance in improving the reliability of power electronic packaging. Full article
(This article belongs to the Special Issue New Welding Materials and Green Joint Technology—2nd Edition)
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