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Metals
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Advanced Metal Welding and Joining Technologies—2nd Edition
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Advanced Metal Welding and Joining Technologies—2nd Edition

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

Deadline for manuscript submissions: 30 September 2025 | Viewed by 3384

Special Issue Editor

Dr. Yu Zhang

E-Mail Website
Guest Editor
Institute of Light Alloy and Processing, Faculty of Materials and Manufacturing, Beijing University of Technology, Beijing 100124, China
Interests: welding metallurgy; light metals; resistance spot welding
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Welding and joining is the key assembling process in modern industry. The application of next-generation structural materials demands novel welding and joining technologies to yield high-quality products. Across this trend, the fundamental research involved not only the evolution of material properties during processing, but also the development of suitable equipment and necessary methods. This Special Issue is focused on advanced metal welding and joining technologies, of which the concerned topics include the following: (1) advanced metals that trigger demands for specific processing techniques; (2) fundamental research on the issue of material evolution during processing; (3) the service performance of the advanced metal joints; and (4) novel welding and joining devices and methods. Furthermore, any research which is related to metal processing technology will also be considered.

Dr. Yu Zhang
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 metallurgy
  • light metals
  • high-entropy alloy
  • bulk metallic glass
  • mechanical property
  • corrosion
  • hybrid joining technique
  • dissimilar metal joining

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Related Special Issue

Published Papers (4 papers)

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Research

20 pages, 15332 KiB  
Article
Synergistic Effects of Thermal Cycles and Residual Stress on Microstructural Evolution and Mechanical Properties in Monel 400 and AISI 316L Weld Joints
by Balram Yelamasetti, Sri Phani Sushma, Zubairuddin Mohammed, Hussain Altammar, Mohammad Faseeulla Khan and Syed Quadir Moinuddin
Metals 2025, 15(5), 469; https://doi.org/10.3390/met15050469 - 22 Apr 2025
Viewed by 197
Abstract
The current study investigates the thermal, metallurgical, and mechanical results in similar and dissimilar weldments of Monel 400 and AISI 316L. Infrared thermography (IRT) was employed to record thermal cycles, while X-ray diffraction (XRD) was used to analyze the residual stresses post-welding. Mechanical [...] Read more.
The current study investigates the thermal, metallurgical, and mechanical results in similar and dissimilar weldments of Monel 400 and AISI 316L. Infrared thermography (IRT) was employed to record thermal cycles, while X-ray diffraction (XRD) was used to analyze the residual stresses post-welding. Mechanical properties were assessed through tensile and microhardness tests, and microstructural evolution was examined using energy-dispersive spectroscopy (EDS) and scanning electron microscopy (SEM). IRT results showed peak temperatures of 1788 °C for Monel 400 and 1750 °C for AISI 316L. Residual stress analysis revealed compressive stresses of 293 MPa in dissimilar welds, compared to 235 MPa in Monel 400 and tensile stresses of 57 MPa in AISI 316L. Ultimate tensile strength (UTS) values were 543 MPa for dissimilar welds, 533 MPa for Monel 400, and 556 MPa for AISI 316L, with corresponding microhardness values of 207 HV, 203 HV, and 168 HV, respectively. Microstructural analysis identified coarse Ni-Cu phases in the Monel 400 heat-affected zone (HAZ), austenitic structures in AISI 316L, and intermetallic compounds in dissimilar welds. The findings highlight the impact of thermal distribution, residual stress, and microstructural evolution on weld performance, providing insights into optimized welding parameters for improved joint integrity and mechanical properties. Full article
(This article belongs to the Special Issue Advanced Metal Welding and Joining Technologies—2nd Edition)
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16 pages, 3976 KiB  
Article
Influence of Augmentation Compositions and Confinement Layers on Flyer Velocity in Laser Impact Welding
by Mohammed Abdelmaola, Brian Thurston, Boyd Panton, Anupam Vivek and Glenn Daehn
Metals 2025, 15(2), 190; https://doi.org/10.3390/met15020190 - 12 Feb 2025
Viewed by 625
Abstract
Small-scale impact welding may have several advantages over rivets: the strength can be higher, it can be applied right at the edges in lap joints, and it can be lighter and more easily installed if simple systems can be developed. Laser Impact Welding [...] Read more.
Small-scale impact welding may have several advantages over rivets: the strength can be higher, it can be applied right at the edges in lap joints, and it can be lighter and more easily installed if simple systems can be developed. Laser Impact Welding (LIW) is compact and simple, adapting the technologies of laser shock peening. It is limited in terms of the energy that can be delivered to the joint. Augmented Laser Impact Welding (ALIW) complements optical energy with a small volume of an exothermic detonable compound and has been shown to be an effective welding approach. The scope of this study is extended to build upon previous work by investigating varied augmentation chemistries and confinement layers, specifically borosilicate glass, sapphire, and water. The evaluation of these compositions involved the use of two aluminum alloys: Al 2024 and Al 6061. Photonic Doppler Velocimetry (PDV) was utilized to measure the flyer velocity and assess the detonation energy. The findings indicated that adding micro-air bubbles (GPN-3 scenario) to the original GPN-1 enhanced the flyer velocity by improving the sensitivity, which promoted gas release during detonation. Hence, employing 1 mm thick Al 2024 as a flyer with GPN-3 enhances the flyer velocity by 36.4% in comparison to GPN-1, thereby improving the feasibility of using 1 mm thick material as a flyer and ensuring a successful welded joint with the thickest flyer ever welded with laser impact welding. When comparing the confinement layers, sapphire provided slightly lower flyer velocities compared to borosilicate glass. However, due to its higher resistance to damage and fracture, sapphire is likely more suitable for industrial applications from an economic perspective. Furthermore, the lap shear tests and microstructural evaluations confirmed that GPN-3 provided higher detonation energy, as emphasized by the tendency of the interfacial waves to have a higher amplitude than the less pronounced waves of the original GPN-1. Consequently, this approach demonstrates the key characteristics of a practical process, being simple, cost-effective, and efficient. Full article
(This article belongs to the Special Issue Advanced Metal Welding and Joining Technologies—2nd Edition)
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17 pages, 17761 KiB  
Article
Calibration of Heat Source Models in Numerical Simulations of Welding Processes
by Tomasz Kik
Metals 2024, 14(11), 1213; https://doi.org/10.3390/met14111213 - 24 Oct 2024
Viewed by 1178
Abstract
This article presents issues related to the methodology of the correct definition of the heat source model in the numerical analyses of welding processes. The problem of determining the input data for the stage of a heat source model definition, obtaining input data [...] Read more.
This article presents issues related to the methodology of the correct definition of the heat source model in the numerical analyses of welding processes. The problem of determining the input data for the stage of a heat source model definition, obtaining input data from experiments, and their proper interpretation and use in defining the numerical model was discussed. Particular attention is paid to the specificity of the problem of defining the heat source model, the way of interpreting the results of the analyses and the way of comparing them with the results of real experiments. The basic problems related to the mapping of the complex geometry of the molten metal pool and the ways to solve them were indicated. The solutions and guidelines presented in the article allow to improve the accuracy and quality of the obtained results of numerical analyses, as well as to shorten the time of preparation of computational models by reducing the number of computational iterations related to the search for the maximum consistency of the compared values and temperature cycles. Full article
(This article belongs to the Special Issue Advanced Metal Welding and Joining Technologies—2nd Edition)
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16 pages, 37083 KiB  
Article
Comparative Study on the Effect of External Magnetic Field on Aluminum Alloy 6061 and 7075 Resistance Spot-Welding Joints
by Shitian Wei, Rui Zhang, Xiuli Liu and Yu Zhang
Metals 2024, 14(10), 1196; https://doi.org/10.3390/met14101196 - 21 Oct 2024
Cited by 1 | Viewed by 1106
Abstract
This study investigates the effects of the external magnetic field on the microstructure and mechanical property aluminum alloy 6061-T6 and 7075-T651 resistance spot welding joints. The melting behavior of 6061 and 7075 was analyzed via the calculation of the phase diagram (CALPHAD) technique. [...] Read more.
This study investigates the effects of the external magnetic field on the microstructure and mechanical property aluminum alloy 6061-T6 and 7075-T651 resistance spot welding joints. The melting behavior of 6061 and 7075 was analyzed via the calculation of the phase diagram (CALPHAD) technique. The CALPHAD results indicate that, for the 6061 aluminum alloy, the liquid fraction shows a minimal increase at the beginning stage during the solid–liquid phase transition process but with a sharp rise at the ending stage (near the liquidus). In contrast, for the 7075 aluminum alloy, the liquid fraction gradually increases throughout the entire solid–liquid phase transition process. The differences in melting behavior between the 6061 and 7075 alloys lead to different liquation crack morphologies in their spot-welded joints. In the 6061 alloy, the cracks tend to be “eyebrow-shaped”, allowing the liquid metal in the nugget to feed the gaps, and this does not significantly compromise the mechanical properties of the joint. In contrast, the 7075 alloy develops slender cracks that extend through the partially melted zone (PMZ), making it difficult for the liquid metal to feed these gaps, thereby significantly deteriorating the joint’s mechanical strength. Compared to conventional resistance spot-welding joints, the heat exchange between the nugget and the workpiece is enhanced under the external magnetic field, leading to a wider PMZ. This exacerbates the detrimental effects of liquation cracks on the mechanical properties of the 7075 joints. Lap-shear tests indicate that the mechanical properties of the 6061 aluminum alloy joints are improved under electromagnetic stirring. For 7075 aluminum alloy joints, the mechanical properties improve when the welding current is below 34 kA. However, when the welding current exceeds 34 kA, because the widening of the PMZ increases the tendency for liquation cracks, the joint’s mechanical property is deteriorated. Full article
(This article belongs to the Special Issue Advanced Metal Welding and Joining Technologies—2nd Edition)
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