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Processes
Special Issues
Advances and Implementation of Welding and Additive Manufacturing
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Advances and Implementation of Welding and Additive Manufacturing

A special issue of Processes (ISSN 2227-9717). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: 10 June 2025 | Viewed by 3119

Special Issue Editors

Dr. Amlan Kar

E-Mail Website
Guest Editor
Arbegast Materials Processing and Joining Laboratory (AMP), South Dakota School of Mines and Technology, Rapid City, SD, USA
Interests: friction stir welding and processing; cold spray; hybrid manufacturing; additive manufacturing; metal forming
Dr. Hrishikesh Das

E-Mail Website
Guest Editor
Pacific Northwest National Laboratory, PO Box 999, Richland, WA 99352, USA
Interests: friction stir welding; solid phase processing; shape; cold spray
Special Issues, Collections and Topics in MDPI journals
Dr. Abhishek Sharma

E-Mail Website
Guest Editor
Joining and Welding Research Institute, Osaka University, Ibaraki, Osaka 560-0047, Japan
Interests: friction stir welding and processing; friction surfacing; material processing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Welding and Additive Manufacturing (AM) hold significant importance in the current industrial scenario, influencing various aspects of production, efficiency, and innovation. Their roles are crucial in shaping and advancing contemporary industrial processes.

This special issue on “Advances and implementation of welding and additive manufacturing” seeks high-quality works focusing on exploring cutting-edge developments and practical applications in the fields of welding and additive manufacturing. As technological advancements continue to reshape these industries, the “Processes” journal invites contributions that delve into the latest breakthroughs, methodologies, and real-world implementations.

Authors are encouraged to submit original research articles, comprehensive reviews, and case studies that showcase novel techniques, materials, and processes within the realm of welding and additive manufacturing.

Topics include, but are not limited to:

  • Optimization and implementation of welding and additive manufacturing
  • Cutting-edge development of new welding and additive manufacturing
  • Hybrid welding and additive manufacturing
  • Digital Twins and Simulation in Welding and Additive Manufacturing
  • Machine learning, industry 4.0; digitalization; internet of things (IoT)
  • Critical implementation of newly developed processes and materials
  • Innovation and Technological Advancements
  • Automation and Robotics in Welding
  • In-Process Monitoring and Control in Additive Manufacturing

Dr. Amlan Kar
Dr. Hrishikesh Das
Dr. Abhishek Sharma
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 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. Processes 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 2400 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
  • additive manufacturing
  • process optimization
  • advancement
  • implementation, automation, simulation, monitoring and control, industry 4.0
  • hybrid approaches

Benefits of Publishing in a Special Issue

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  • Greater discoverability: Special Issues support the reach and impact of scientific research. Articles in Special Issues are more discoverable and cited more frequently.
  • Expansion of research network: Special Issues facilitate connections among authors, fostering scientific collaborations.
  • External promotion: Articles in Special Issues are often promoted through the journal's social media, increasing their visibility.
  • Reprint: MDPI Books provides the opportunity to republish successful Special Issues in book format, both online and in print.

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

Published Papers (2 papers)

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21 pages, 11884 KiB  
Article
Process Parameters and Heat-Treatment Optimization for Improving Microstructural and Mechanical Properties of AA6082-T651 Deposit on EN14B Plate Using Friction Surfacing Technique
by Hemlata Jangid, Nirmal K. Singh and Amlan Kar
Processes 2025, 13(3), 637; https://doi.org/10.3390/pr13030637 - 24 Feb 2025
Viewed by 590
Abstract
Friction surfacing (FS) is increasingly recognized as an advanced technique for coating similar and dissimilar materials, enabling superior joint quality through plastic deformation and grain refinement. This study investigates the deposition of AA6082-T651 alloy on a medium-carbon steel EN14B substrate using FS, with [...] Read more.
Friction surfacing (FS) is increasingly recognized as an advanced technique for coating similar and dissimilar materials, enabling superior joint quality through plastic deformation and grain refinement. This study investigates the deposition of AA6082-T651 alloy on a medium-carbon steel EN14B substrate using FS, with process parameters optimized, and the effect of axial load, rotational speed, and traverse speed on coating integrity. The optimal sample was subjected to heat treatment (HT) at 550 °C for 24, 36, and 48 h to further enhance mechanical properties. Comprehensive microstructural and mechanical analyses were performed on both heat-treated and non-heat-treated samples using optical microscopy (OM), field emission scanning electron microscopy (FESEM) with energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), microhardness testing, and micro-tensile techniques. The optimized sample was processed with a 6 kN axial load, a rotational speed of 2700 rpm, and a traverse speed of 400 mm/min, and demonstrated superior bond quality and enhanced mechanical properties. The highest interfacial hardness values, 138 HV0.1 were achieved for the sample annealed for 48 h, under an axial load of 6 kN. Annealing for 48 h significantly improved atomic bonding at the aluminum–steel interface, confirmed by the formation of Fe3Al intermetallic compounds detected via FESEM-EDS and XRD. These compounds were the primary reason for the enhancement in the mechanical properties of the FS deposit. Furthermore, the interrelationship between process and thermal parameters revealed that a peak temperature of 422 °C, heat input of 1.1 kJ/mm, and an axial load of 6 kN are critical for achieving optimal mechanical interlocking and superior coating quality. The findings highlight that optimized FS parameters and post-heat treatment are critical in achieving high-quality, durable coatings, with improved interfacial bonding and hardness, making the process suitable for structural applications. Full article
(This article belongs to the Special Issue Advances and Implementation of Welding and Additive Manufacturing)
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19 pages, 8718 KiB  
Article
Comparison of Mechanical, Fatigue, and Corrosion Properties of Fusion-Welded High-Strength AA6011 Alloy Using Three Filler Wires
by Mohamed Ahmed, Mousa Javidani, Alexandre Maltais and X.-Grant Chen
Processes 2024, 12(6), 1172; https://doi.org/10.3390/pr12061172 - 7 Jun 2024
Cited by 2 | Viewed by 1203
Abstract
In this study, the welding performance of three filler wires, ER4043, ER5356, and the newly developed FMg0.6, were systematically investigated in the gas metal arc welding of high-strength AA6011-T6 plates. An extensive analysis of the microstructural evolution, mechanical properties, fatigue resistance, and corrosion [...] Read more.
In this study, the welding performance of three filler wires, ER4043, ER5356, and the newly developed FMg0.6, were systematically investigated in the gas metal arc welding of high-strength AA6011-T6 plates. An extensive analysis of the microstructural evolution, mechanical properties, fatigue resistance, and corrosion behavior of different weldments was conducted. The ER4043 and FMg0.6 joints exhibited finer grain sizes in the fusion zone (FZ) than the ER5356 joint. The as-welded ER5356 and FMg0.6 joints exhibited higher hardness and tensile strength values than the ER4043 joint. The FMg0.6 joint demonstrated the highest mechanical strength among all of the joints with superior fatigue resistance under both the as-welded and post-weld heat treatment (PWHT) conditions. In the as-welded state, the ER5356 joint exhibited the lowest corrosion resistance, attributed to the precipitation of β-Al2Mg3 at the grain boundaries. The FMg0.6 joint, characterized by a high-volume fraction of eutectic Mg2Si in the as-welded state, exhibited a higher corrosion rate than that of the ER4043 joint. However, the PWHT effectively improved the corrosion resistance of the FMg0.6 joint. Given its excellent tensile properties, superior fatigue properties, and satisfactory corrosion resistance, particularly with PWHT, the newly developed FMg0.6 filler has emerged as a promising candidate for welding high-strength 6xxx alloys. Full article
(This article belongs to the Special Issue Advances and Implementation of Welding and Additive Manufacturing)
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