Microstructure and Mechanical Properties of Dissimilar Metal Welding

A Special Issue of Metals (ISSN 2075-4701) belonging to the section "Welding and Joining".

Deadline for manuscript submissions: 31 January 2027 | Viewed by 300

Editors

School of Materials Science and Engineering, Kunming University of Science and Technology, Kunming, China
Interests: brazing; diffusion bonding; dissimilar materials joining

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Guest Editor
Department of Engineering and Management, University of Padova, Stradella San Nicola 3, 36100 Vicenza, Italy
Interests: raw materials; structural integrity of welded joints and additively manufactured components; welding and heat treatment simulation; cast iron; stainless steels; material selection
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Special Issue Information

Dear Colleagues,

The joining of dissimilar metals is a key enabling technology for the manufacture of lightweight, high-performance and multifunctional structural components in aerospace, transportation, energy, marine, nuclear and advanced manufacturing industries. By combining the advantages of different metallic materials, dissimilar metal welding provides an effective route to optimize structural weight, service performance and cost. However, the large differences in the physical, chemical, metallurgical and mechanical properties between dissimilar metals often lead to complex interfacial reactions, brittle intermetallic compound formation, residual stress concentration and premature failure. Therefore, understanding the relationship between the welding process, interfacial microstructure and mechanical properties is of great significance for both scientific research and engineering applications.

This Special Issue, “Microstructure and Mechanical Properties of Dissimilar Metal Welding”, aims to present and disseminate the latest advances in the welding and joining of dissimilar metallic materials. We welcome original research articles and review papers focusing on, but not limited to, brazing, diffusion bonding, fusion welding, solid-state welding, additive manufacturing-assisted joining and other advanced joining techniques for dissimilar metals. Contributions addressing interfacial microstructure evolution, phase formation, residual stress, mechanical performance, fracture behavior, strengthening and toughening mechanisms, numerical simulation and service reliability are particularly encouraged. It is our pleasure to invite you to submit a manuscript for this Special Issue.

Dr. Xin Nai
Prof. Dr. Paolo Ferro
Guest Editors

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Keywords

  • metallurgical reaction
  • intermetallics
  • mechanical properties
  • thermal mismatch
  • residual stress

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Published Papers (1 paper)

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Research

15 pages, 12772 KB  
Article
Coupling Effects of Ultrasonic Assistance and Self-Riveting on the Dissimilar Al/Mg Friction Stir Lap Weld Performance
by Yu Chen, Yikang Zhang, Sijia Wang, Xiaolin Liu and Hailiang Yu
Metals 2026, 16(9), 1018; https://doi.org/10.3390/met16091018 - 12 Sep 2026
Abstract
In this work, conventional friction stir lap welding (FSLW), self-riveting FSLW (R-FSLW) and ultrasonic-assisted R-FSLW (UR-FSLW) were employed to join dissimilar AA6061 and AZ31 alloys. The relatively thick Al-Mg intermetallic compound (IMC) layer provided limited metallurgical bonding, causing the FSLW joint to fail [...] Read more.
In this work, conventional friction stir lap welding (FSLW), self-riveting FSLW (R-FSLW) and ultrasonic-assisted R-FSLW (UR-FSLW) were employed to join dissimilar AA6061 and AZ31 alloys. The relatively thick Al-Mg intermetallic compound (IMC) layer provided limited metallurgical bonding, causing the FSLW joint to fail in a brittle manner at a low tensile shear force of 875 N. The self-riveting introduced additional mechanical interlocking: the R-FSLW joint, featuring AA6061 rivets, exhibited a 22% increase in tensile shear force compared with the FSLW joint. Nevertheless, cracks formed along the thick Al-Mg IMC layer around the AA6061 rivets, which retained the brittle fracture characteristic. In contrast, ultrasonic assistance not only improved the rivet filling rate (reducing the unfilled area from 0.83 mm2 to 0.61 mm2) but also suppressed Al-Mg IMC layer growth and eliminated cracks. Moreover, ultrasonic assistance increased the stored energy and promoted material flow, refining the grains in the nugget zone (NZ) and thereby raising the average hardness of NZ. Consequently, with AA6061 rivets and refined microstructures, the UR-FSLW joint delivered a tensile shear force of 1280 N and an elongation double that of the FSLW joint, accompanied by a fracture mode transition from brittle to ductile-brittle. Full article
(This article belongs to the Special Issue Microstructure and Mechanical Properties of Dissimilar Metal Welding)
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