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Metals
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Novel Insights into Welding and Joining Technologies of Metallic Materials
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Novel Insights into Welding and Joining Technologies of Metallic Materials

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

Deadline for manuscript submissions: 30 June 2026 | Viewed by 2228

Special Issue Editors

Dr. Haifeng Yang

E-Mail Website
Guest Editor
State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001, China
Interests: welding and joining of materials; metal materials; surface modification of materials
Dr. Meirong Wang

E-Mail Website
Guest Editor
State Key Laboratory of Advanced Welding and Joining, Harbin Institute of Technology, Harbin 150001, China
Interests: welding and joining of materials; composite materials

Special Issue Information

Dear Colleagues,

Welding, a crucial process in material engineering, has been widely applied across diverse industrial sectors, including aerospace, energy, and transportation. With the development of new materials and technologies, such as electronics, computers, and robotics, welding science has achieved remarkable progress. However, new materials and components pose higher demands on welding processes and materials, spurring innovation in traditional techniques for new materials, along with the development of new welding processes and connection technologies.

In this Special Issue, we welcome a variety of research works on innovative welding materials, novel welding processes, additive manufacturing, and in-depth exploration of the microstructure, performance, and interface behavior of welded joints to enhance the quality and reliability of welded structures.

Dr. Haifeng Yang
Dr. Meirong Wang
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 250 words) can be sent to the Editorial Office for assessment.

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 technology
  • welded joints
  • new materials
  • connection

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Further information on MDPI's Special Issue policies can be found here.

Published Papers (4 papers)

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Research

19 pages, 6735 KB  
Article
Innovative Metal–Polymer Composite Panels with Integrated Channels for Thermal Management Systems Using Hybrid Friction Stir Channeling—HFSC
by Arménio N. Correia, Virgínia Infante, Daniel F. O. Braga, Ricardo Baptista and Pedro Vilaça
Metals 2026, 16(1), 16; https://doi.org/10.3390/met16010016 - 24 Dec 2025
Viewed by 239
Abstract
In this research, we assess the feasibility of employing hybrid friction stir channeling (HFSC) to produce composite panels that combined an 8 mm thick AA6082-T6 aluminum alloy and 5 mm thick glass-fiber-reinforced Noryl GFN2. HFSC is an innovative solid-state technology that combines both [...] Read more.
In this research, we assess the feasibility of employing hybrid friction stir channeling (HFSC) to produce composite panels that combined an 8 mm thick AA6082-T6 aluminum alloy and 5 mm thick glass-fiber-reinforced Noryl GFN2. HFSC is an innovative solid-state technology that combines both friction stir joining and channeling characteristics, which enable the generation of integral internal channels while joining different components. A parametric study was outlined to explore the effects of the travel speed, probe length, and tool plunging on the resulting composite panels. The resulting composite panels were subsequently subjected to a comprehensive analysis encompassing exterior ceiling quality, internal channel, and joining interface morphology. Depending on the processing parameters, the geometry of the channels was found to be quasi-rectangular or quasi-trapezoidal, with significant variability on cross-sectional area, resulting in hydraulic diameters ranging from 1.2 to 2.9 mm. The joining interface was characterized by a concavity of aluminum that was extruded downwards into the polymeric molten pool, which was clinched after polymeric re-solidification. The experimental results prove the ability to join metals and polymers while creating an integral channel in a single process step using HFSC. Despite the positive effect of irregular shaped channels on heat exchange, the numerical models evidenced a detrimental effect of 14.3 and 16.3% on ultimate tensile and flexural loads, respectively. This way, this fabrication technology evidenced promising characteristics that are suitable for manufacturing thermal management systems such as conformal cooling for plastic injection molding or battery trays for EVs. Full article
(This article belongs to the Special Issue Novel Insights into Welding and Joining Technologies of Metallic Materials)
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16 pages, 9806 KB  
Article
Structure and Properties of Stainless Steel–Thermoplastic Joints Made Using Resistance Element Soldering Technology
by Pavol Sejč, Pavol Švec, Peter Gogola, Branislav Vanko, Zuzana Gábrišová, Alexander Schrek and Miroslav Zelina
Metals 2026, 16(1), 6; https://doi.org/10.3390/met16010006 - 20 Dec 2025
Viewed by 228
Abstract
This study investigated the microstructure and properties of soldered joints of AISI 304 stainless steel and PMMA thermoplastic or AW-1050A aluminum alloys made using Resistance Element Soldering (RES) technology. The bimetallic element used in RES provided a mechanical joint with a thermoplastic or [...] Read more.
This study investigated the microstructure and properties of soldered joints of AISI 304 stainless steel and PMMA thermoplastic or AW-1050A aluminum alloys made using Resistance Element Soldering (RES) technology. The bimetallic element used in RES provided a mechanical joint with a thermoplastic or aluminum alloy and a soldered joint with AISI 304 steel using Sn60Pb40 solder in the core of the element. The solder in combination with the Chemet CHM-A-014 flux wetted the AISI 304 steel surface very well at a temperature of 225 °C with a contact angle of 14°. During the production of the joints, the solder melted in the bimetallic element on the AISI 304 steel side, while solid solder was retained at the point of contact with the welding electrode. The strength of the joints ranged from 25.5 to 36.4 MPa, which was less than the strength of the solder, and the joints failed at the AISI 304 steel–Sn60Pb40 solder interface. The fracture surface was predominantly formed by the solder. An intermetallic phase of FeSn2 was identified at the interface. Full article
(This article belongs to the Special Issue Novel Insights into Welding and Joining Technologies of Metallic Materials)
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27 pages, 13345 KB  
Article
Micro and Macrostructural Assessment of Welded 6082 Aluminium Alloy T-Connections
by Darko Landek, Ivica Garašić, Davor Skejić, Anđelo Valčić, Ivan Čudina and Mislav Štefok
Metals 2025, 15(12), 1365; https://doi.org/10.3390/met15121365 - 11 Dec 2025
Viewed by 334
Abstract
One of the main challenges in welding aluminium concerns structural integrity and a significant reduction in mechanical properties in the region adjacent to the weld. Design provisions can result in a drastic reduction, which may exceed 50% of the base metal resistance. This [...] Read more.
One of the main challenges in welding aluminium concerns structural integrity and a significant reduction in mechanical properties in the region adjacent to the weld. Design provisions can result in a drastic reduction, which may exceed 50% of the base metal resistance. This research aims to evaluate the accuracy of the HAZ extent values codified in Eurocode 9 for T-connections fabricated from artificially aged 6082 aluminium alloy, which is widely used in load-bearing structures. Three plate thicknesses (6, 8 and 10 mm) and two pulsed MIG welding processes (DC-MIG-P and AC-MIG-P) were used to fabricate 20 T-connection specimens (10 different configurations) in accordance with EN 1090-3. The study focuses on characterising the welding zones through hardness testing and metallographic examination. Results show that AC-MIG-P offers better control over thermal input and may reduce structural distortion, while DC-MIG-P provides more robust fusion and metallurgical continuity. Findings related to HAZ extent (12.77 mm and 15.36 mm maximum measured for AC-MIG-P and DC-MIG-P, respectively) suggest that Eurocode 9 may be overly conservative for pulsed MIG welding processes, particularly for greater plate thicknesses where a HAZ extent of 22.50 mm or more is specified. Consequently, adopting more precise, process-specific HAZ characterisations could lead to more realistic connection design and structural behaviour. Full article
(This article belongs to the Special Issue Novel Insights into Welding and Joining Technologies of Metallic Materials)
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18 pages, 8946 KB  
Article
Dissimilar Resistance Spot Weld of Ni-Coated Aluminum to Ni-Coated Magnesium Using Cold Spray Coating Technology
by Mazin Oheil, Dulal Saha, Hamid Jahed and Adrian Gerlich
Metals 2025, 15(9), 940; https://doi.org/10.3390/met15090940 - 24 Aug 2025
Viewed by 1097
Abstract
Direct fusion welding of aluminum (Al) to magnesium (Mg) results in the formation of brittle intermetallic compounds (IMCs) that significantly restrict the application of these joints in structural applications. In this study, cold spray, a promising solid-state coating deposition technology, was employed to [...] Read more.
Direct fusion welding of aluminum (Al) to magnesium (Mg) results in the formation of brittle intermetallic compounds (IMCs) that significantly restrict the application of these joints in structural applications. In this study, cold spray, a promising solid-state coating deposition technology, was employed to introduce a nickel (Ni) interlayer to facilitate joining of Al to Mg sheets by means of resistance spot welding (RSW). The ability of cold spraying to deposit metallic powder on the substrate without melting proves beneficial in mitigating the formation of the Al-Mg IMCs. The Ni-coated coupons were subsequently welded via resistance spot welding at optimized parameters: 27 kA for 15 cycles in two pulses with a 5-cycle inter-pulse delay. Scanning electron microscopy confirmed metallurgical bonding between the Al, Mg, and Ni coatings in the fusion zone. It is shown that the bonding between the three elements inhibits the formation of deleterious IMCs. Tensile shear testing showed joint strength exceeding 4.2 kN, highlighting the potential of the proposed cold spray RSW approach for dissimilar joining in structural applications. Full article
(This article belongs to the Special Issue Novel Insights into Welding and Joining Technologies of Metallic Materials)
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