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Metals
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Modeling and Mechanism Analysis of Welding Process for Metals
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Modeling and Mechanism Analysis of Welding Process for Metals

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

Deadline for manuscript submissions: 15 June 2025 | Viewed by 2963

Special Issue Editor

Dr. Kang Zhou

E-Mail Website
Guest Editor
School of Mechatronical Engineering, Beijing Institute of Technology, Beijing 100081, China
Interests: finite element modeling of welding process; electrical engineering; mechatronics; intelligent control of welding systems
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Recently, welding processes have made rapid progress in various industrial areas. New welding methods, techniques, and many auxiliary tools and instruments are presented. Their modeling and mechanism analysis involve a large number of schemes. By modeling using proper mathematical tools, detailed mechanism analyses can be conducted, which are effective tools to facilitate new welding techniques.

We welcome any new techniques and methods regarding the welding process, such as welding processes between dissimilar metals or metals and new compound materials. In addition, any auxiliary tools, such as ultrasonic assistance, external magnetic assistance, or a combination of two or more welding techniques, are strongly welcome. We believe that this new Special Issue will be an effective platform to present new progress in the field of welding. 

Dr. Kang Zhou
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

  • metals
  • welding
  • modeling
  • mechanism
  • process signal
  • finite element
  • dissimilar materials
  • composite material
  • artificial intelligence

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

Published Papers (3 papers)

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Research

22 pages, 20741 KiB  
Article
Microstructure and Properties of Resistance Element Welded Joints of DP780 Steel and 6061 Aluminum Alloy
by Qinglong Wu, Yue Yang, Yingzhe Li, Qing Guo, Shuyue Luo and Zhen Luo
Metals 2025, 15(3), 283; https://doi.org/10.3390/met15030283 - 5 Mar 2025
Viewed by 509
Abstract
This study developed a metallurgical and mechanical hybrid resistance element welding (REW) method to fabricate lightweight Al/steel joints between 2.0 mm 6061 aluminum alloy and 1.2 mm DP780 steel, addressing critical challenges of interfacial intermetallic compounds (IMC layer thickness: 4.6–8.3 μm) in dissimilar [...] Read more.
This study developed a metallurgical and mechanical hybrid resistance element welding (REW) method to fabricate lightweight Al/steel joints between 2.0 mm 6061 aluminum alloy and 1.2 mm DP780 steel, addressing critical challenges of interfacial intermetallic compounds (IMC layer thickness: 4.6–8.3 μm) in dissimilar metal welding. In addition, the scanning electron microscope (SEM), electron backscatter diffraction (EBSD), and electron probe microanalysis (EPMA) were used to observe the microstructure characteristics and element distribution. The lath martensite and solidification microstructure were observed in the steel-nugget zone and Al-nugget zone, respectively. Furthermore, the microhardness distribution, volume fraction of the α phase, tensile–shear load, and failure mode of REWed joint were studied. Process optimization demonstrated welding current’s pivotal role in joint performance, achieving a maximum tensile–shear load of 6914.1 N under 10 kA conditions with a button pull-out failure (BPF) mechanism. Full article
(This article belongs to the Special Issue Modeling and Mechanism Analysis of Welding Process for Metals)
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17 pages, 6891 KiB  
Article
Weld Bead Shape and Formation Prediction for Robotic MIG Welding Process Using Numerical Calculation
by Ping Yao, Yunyi Huang, Riheng He, Junxi Huang, Meiyi Chen, Wenxiao Yu and Kang Zhou
Metals 2025, 15(2), 168; https://doi.org/10.3390/met15020168 - 8 Feb 2025
Viewed by 668
Abstract
To optimize the robotic MIG welding process for joining 316 L stainless steel sheets and to clearly understand the process, a new numerical model for a combined heat source, based on a Gaussian surface and Gaussian cylinder, was developed using ANSYS software. After [...] Read more.
To optimize the robotic MIG welding process for joining 316 L stainless steel sheets and to clearly understand the process, a new numerical model for a combined heat source, based on a Gaussian surface and Gaussian cylinder, was developed using ANSYS software. After confirming the proper welding parameter combination for producing a weld bead with a good appearance, the model could be developed using the parameter combination. The influence of four parameters—effective heat delivery radius, the depth and heat distribution coefficients of the Gaussian surface, and the Gaussian cylinder heat source effects on the bead width and penetration—was explored using the model, and then a general and convenient method was proposed to effectively and reasonably set the parameters of the combined heat source. Finally, the numerical calculation results for the shape of the fusion line of the weld bead section could be obtained under different input powers and different welding speeds. The numerical calculation results had small errors compared to the experiments results. Hence, this model could realize temperature field simulation and weld bead formation prediction. This work can be used to accurately and effectively predict the robotic MIG welding process in the academic research and supply references for actual production. Full article
(This article belongs to the Special Issue Modeling and Mechanism Analysis of Welding Process for Metals)
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14 pages, 2167 KiB  
Article
A Comprehensive Material Model for the Super-Duplex Stainless Steel SAF2507 in a Welding Environment
by Maximilian Prunbauer, Peter Raninger, Werner Ecker, Martin Rester and Reinhold Ebner
Metals 2024, 14(2), 153; https://doi.org/10.3390/met14020153 - 26 Jan 2024
Viewed by 1380
Abstract
The aim of this work is to describe a reliable methodology for determining parameters of a material model suitable for implementation in a welding simulation using the finite element method (FEM). The adopted methodology employs a multi-scale approach integrating a microstructure evolution model, [...] Read more.
The aim of this work is to describe a reliable methodology for determining parameters of a material model suitable for implementation in a welding simulation using the finite element method (FEM). The adopted methodology employs a multi-scale approach integrating a microstructure evolution model, a representative volume element (RVE) calibrated through experimental methods, including a thermal–mechanical simulator, and electron backscatter diffraction (EBSD) experiments. The result is a complete material model, which covers thermal, mechanical and metallurgical material models for SAF2507 (EN 1.4410), that shows promising results and was successfully implemented in finite element (FE) code. A direct comparison of experimental and calculated results shows a deviation of up to 12% for the phase fraction of austenite and 25% for the mean grain diameter of ferrite. Full article
(This article belongs to the Special Issue Modeling and Mechanism Analysis of Welding Process for Metals)
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