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Search Results (578)

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19 pages, 2616 KiB  
Article
Structural Analysis of Joints Made of Titanium Alloy TI-6AL-4V and Stainless Steel AISI 321 with Developed Conical Contact Surfaces Obtained by Diffusion Welding
by Olena Karpovych, Ivan Karpovych, Oleksii Fedosov, Denys Zhumar, Yevhen Karakash, Miroslav Rimar, Jan Kizek and Marcel Fedak
Materials 2025, 18(15), 3596; https://doi.org/10.3390/ma18153596 (registering DOI) - 31 Jul 2025
Viewed by 154
Abstract
The object of this study is welded joints of AISI 321 and Ti-6Al-4V, obtained by diffusion welding on developed conical surfaces. The problem of creating bimetallic joints of AISI 321 and Ti-6Al-4V with developed conical contact surfaces, using diffusion welding through an intermediate [...] Read more.
The object of this study is welded joints of AISI 321 and Ti-6Al-4V, obtained by diffusion welding on developed conical surfaces. The problem of creating bimetallic joints of AISI 321 and Ti-6Al-4V with developed conical contact surfaces, using diffusion welding through an intermediate Electrolytic Tough Pitch Copper (Cu-ETP) copper layer, was solved. The joints were studied using micro-X-ray spectral analysis, microstructural analysis, and mechanical tests. High mutual diffusion of copper and titanium, along with increased concentrations of Cr and V in copper, was detected. The shear strength of the obtained welded joints is 250 MPa and 235 MPa at 30 min and 15 min, respectively, which is higher than the copper layer’s strength (180 MPa). The obtained results are explained by the dislocation diffusion mechanism in the volume of grains and beyond, due to thermal deformations during welding. Under operating conditions of internal pressure and cryogenic temperatures, the strength of the connection is ensured by the entire two-layer structure, and tightness is ensured by a vacuum-tight diffusion connection. The obtained strength of the connection (250 MPa) is sufficient under the specified operating conditions. Analysis of existing solutions in the literature review indicates that industrial application of technology for manufacturing bimetallic adapters from AISI 321 stainless steel and Ti-6Al-4V titanium alloy is limited to butt joints with small geometric dimensions. Studies of the transition zone structure and diffusion processes in bimetallic joints with developed conical contact surfaces enabled determination of factors affecting joint structure and diffusion coefficients. The obtained bimetallic adapters, made of Ti-6Al-4V titanium alloy and AISI 321 stainless steel, can be used to connect titanium high-pressure vessels with stainless steel pipelines. Full article
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18 pages, 5418 KiB  
Article
Effect and Mechanism Analysis of Process Parameters and Penetration State on Pore Defects of 1060/2A12 Dissimilar Aluminum Alloy Electron Beam Welding Joints
by Guolong Ma, Gangqing Li, Xiaohui Han, Chenghui Jiang, Zengci Cheng, Wangzhan Diao and Houqin Wang
Materials 2025, 18(15), 3477; https://doi.org/10.3390/ma18153477 - 24 Jul 2025
Viewed by 197
Abstract
Pore defects are one of the most common defects in the aluminum alloy electron beam welding process. In this paper, research on the pore defects and related mechanisms of the electron beam welding of dissimilar aluminum alloys was carried out with 1060 and [...] Read more.
Pore defects are one of the most common defects in the aluminum alloy electron beam welding process. In this paper, research on the pore defects and related mechanisms of the electron beam welding of dissimilar aluminum alloys was carried out with 1060 and 2A12 aluminum alloys. Under the test conditions, the pore defects of the aluminum alloy joint were related to the penetration status, the porosity of the critically penetrated joint was low, and the porosity of the beam joint increased when it was slightly penetrated. When the welding speed changed from 300 mm/min to 1200 mm/min, the porosity in the critically penetrated joint first increased and then decreased. When the welding speed was set to 300 mm/min and the beam current was set to 26 mA, the porosity of the joints reached its minimum value at 0.23%. Based on the actual process of electron beam welding, a flow simulation model was established to study the aluminum alloy welding process. The stability of the keyhole was related to the electron beam energy density reaching the inner keyhole, so increasing the electron beam for the fully penetrated joints was advantageous for reducing the pore defects. Full article
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15 pages, 7193 KiB  
Article
Effects of Defocus Distance and Weld Spacing on Microstructure and Properties of Femtosecond Laser Welded Quartz Glass-TC4 Alloy Joints with Residual Stress Analysis
by Gang Wang, Runbo Zhang, Xiangyu Xu, Ren Yuan, Xuteng Lv and Chenglei Fan
Materials 2025, 18(14), 3390; https://doi.org/10.3390/ma18143390 - 19 Jul 2025
Viewed by 234
Abstract
This study develops an optimized femtosecond laser welding process for joining quartz glass and TC4 titanium alloy (Ti-6Al-4V) under non-optical contact conditions, specifically addressing the manufacturing needs of specialized photoelectric effect research containers. The joint primarily consists of parallel laser-welded zones (WZ) interspersed [...] Read more.
This study develops an optimized femtosecond laser welding process for joining quartz glass and TC4 titanium alloy (Ti-6Al-4V) under non-optical contact conditions, specifically addressing the manufacturing needs of specialized photoelectric effect research containers. The joint primarily consists of parallel laser-welded zones (WZ) interspersed with base material. The defocus distance of the femtosecond laser predominantly influences the depth and phase composition of the WZ, while the weld spacing influences the crack distribution in the joint region. The maximum shear strength of 14.4 MPa was achieved at a defocusing distance of +0.1 mm (below the interface) and a weld spacing of 40 μm. The XRD stress measurements indicate that the defocusing distance mainly affects the stress along the direction of laser impact (DLI), whereas the weld spacing primarily influences the stress along the direction of spacing (DS). GPA results demonstrate that when the spacing is less than 30 μm, the non-uniform shrinkage inside the WZ induces tensile stress in the joint, leading to significant fluctuations in DS residual stress and consequently affecting the joint’s shear strength. This study investigates the effects of process parameters on the mechanical properties of dissimilar joints and, for the first time, analyzes the relationship between joint residual strain and femtosecond laser weld spacing, providing valuable insights for optimizing femtosecond laser welding processes. Full article
(This article belongs to the Section Manufacturing Processes and Systems)
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16 pages, 8314 KiB  
Article
Effect of the Heat Affected Zone Hardness Reduction on the Tensile Properties of GMAW Press Hardening Automotive Steel
by Alfredo E. Molina-Castillo, Enrique A. López-Baltazar, Francisco Alvarado-Hernández, Salvador Gómez-Jiménez, J. Roberto Espinosa-Lumbreras, José Jorge Ruiz Mondragón and Víctor H. Baltazar-Hernández
Metals 2025, 15(7), 791; https://doi.org/10.3390/met15070791 - 13 Jul 2025
Viewed by 369
Abstract
An ultra-high-strength press-hardening steel (PHS) and a high-strength dual-phase steel (DP) were butt-joined by the gas metal arc welding (GMAW) process, aiming to assess the effects of a high heat input welding process on the structure-property relationship and residual stress. The post-weld microstructure, [...] Read more.
An ultra-high-strength press-hardening steel (PHS) and a high-strength dual-phase steel (DP) were butt-joined by the gas metal arc welding (GMAW) process, aiming to assess the effects of a high heat input welding process on the structure-property relationship and residual stress. The post-weld microstructure, the microhardness profile, the tensile behavior, and the experimentally obtained residual stresses (by x-ray diffraction) of the steels in dissimilar (PHS-DP) and similar (PHS-PHS, DP-DP) pair combinations have been analyzed. Results indicated that the ultimate tensile strength (UTS) of the dissimilar pair PHS-DP achieves a similar strength to the DP-DP joint, whereas the elongation was similar to that of the PHS-PHS weldment. The failure location of the tensile specimens was expected and systematically observed at the tempered and softer sub-critical heat-affected zone (SC-HAZ) in all welded conditions. Compressive residual stresses were consistently observed along the weldments in all specimens; the more accentuated negative RS were measured in the PHS joint attributed to the higher volume fraction of martensite; furthermore, the negative RS measured in the fusion zone (FZ) could be well correlated to weld restraint due to the sheet anchoring during the welding procedure, despite the presence of predominant ferrite and pearlite microstructures. Full article
(This article belongs to the Special Issue Welding and Joining of Advanced High-Strength Steels (2nd Edition))
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28 pages, 7820 KiB  
Review
Mechanisms and Performance of Composite Joints Through Adhesive and Interlocking Means—A Review
by Khishigdorj Davaasambuu, Yu Dong, Alokesh Pramanik and Animesh Kumar Basak
J. Compos. Sci. 2025, 9(7), 359; https://doi.org/10.3390/jcs9070359 - 10 Jul 2025
Viewed by 804
Abstract
Conventional adhesively bonded joints, such as single-lap, curved-lap, wavy-lap, double-lap, stepped-lap, and scarf joints, are widely used for aerospace, automotive, and medical applications. These adhesively bonded joints exhibit different load transfer mechanisms and stress distributions within adhesive layers, which depend primarily on their [...] Read more.
Conventional adhesively bonded joints, such as single-lap, curved-lap, wavy-lap, double-lap, stepped-lap, and scarf joints, are widely used for aerospace, automotive, and medical applications. These adhesively bonded joints exhibit different load transfer mechanisms and stress distributions within adhesive layers, which depend primarily on their geometries and mechanical properties of bonded materials. As such, joint geometry and material properties play a critical role in determining the capability of the joints to withstand high loads, resist fatigue, and absorb energy under impact loading. This paper investigates the effects of geometry and material dissimilarity on the performance of both conventional bonded and interlocking joints under tensile loading based on the information available in the literature. In addition, bonding and load transfer mechanisms were analysed in detail. It was found that stress concentration often occurs at free edges of the adhesive layer due to geometric discontinuities, while most of the load is carried by these regions rather than its centre. Sharp corners further intensify resulting stresses, thereby increasing the risk of joint failure. Adhesives typically resist shear loads better than peel loads, and stiffness mismatches between adherents induce an asymmetric stress distribution. Nonetheless, similar materials promote symmetric load sharing. Among conventional joints, scarf joints provide the most uniform load distribution. In interlocking joints such as dovetail, T-slot, gooseneck, and elliptical types, the outward bending of the female component under tension can lead to mechanical failure. Full article
(This article belongs to the Special Issue Mechanical Properties of Composite Materials and Joints)
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29 pages, 8611 KiB  
Article
Study of Corrosion Resistance of Hybrid Structure of DP980 Two-Phase Steel and Laser-Welded 6013-T4 Aluminum Alloy
by Antonio Faria Neto, Erica Ximenes Dias, Francisco Henrique Cappi Freitas, Cristina Sayuri Fukugauchi, Erick Siqueira Guidi, Marcelo Sampaio Martins, Antonio Jorge Abdalla and Marcelo dos Santos Pereira
J. Manuf. Mater. Process. 2025, 9(7), 237; https://doi.org/10.3390/jmmp9070237 - 9 Jul 2025
Viewed by 438
Abstract
The future of the automotive industry appears to hinge on the integration of dissimilar materials, such as aluminum alloys and carbon steel. However, this combination can lead to galvanic corrosion, compromising the structural integrity. In this study, laser-welded joints of 6013-T4 aluminum alloy [...] Read more.
The future of the automotive industry appears to hinge on the integration of dissimilar materials, such as aluminum alloys and carbon steel. However, this combination can lead to galvanic corrosion, compromising the structural integrity. In this study, laser-welded joints of 6013-T4 aluminum alloy and DP980 steel were evaluated for their morphology, microhardness, and corrosion resistance. Corrosion resistance was assessed using the electrochemical noise technique over time in 0.1 M Na2SO4 and 3.5% NaCl solutions. The wavelet function was applied to remove the DC trend, and energy diagrams were generated to identify the type of corrosive process occurring on the electrodes. Corrosion on the electrodes was also monitored using photomicrographic images. Analysis revealed an aluminum–steel mixture in the melting zone, along with the presence of AlFe, AlFe3, and AlI3Fe4 intermetallic compounds. The highest Vickers microhardness was observed in the heat-affected zone, adjacent to the melt zone, where a martensitic microstructure was identified. The 6013-T4 aluminum alloy demonstrated the highest corrosion resistance in both media. Conversely, the electrochemical noise resistance was similar for the DP980 steel and the weld bead, indicating that the laser welding process does not significantly impact this property. The energy diagrams showed that localized pitting corrosion was the predominant form of corrosion. However, generalized and mixed corrosion were also observed, which corroborated the macroscopic analysis of the electrodes. Full article
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20 pages, 13331 KiB  
Article
Numerical Simulation of Seabed Response Around Monopile Under Wave–Vibration
by Hongyi Du, Dunge Wang, Jiankang Hou, Ziqin Yu, Ze Liu and Yongzhou Cheng
J. Mar. Sci. Eng. 2025, 13(7), 1309; https://doi.org/10.3390/jmse13071309 - 6 Jul 2025
Viewed by 281
Abstract
Monopile foundation is an important foundation form for offshore wind turbines, and the stability of the seabed around it is affected by the combined effects of wave and pile vibration. Based on the Biot consolidation theory and elastoplastic constitutive model, a multi-physical field [...] Read more.
Monopile foundation is an important foundation form for offshore wind turbines, and the stability of the seabed around it is affected by the combined effects of wave and pile vibration. Based on the Biot consolidation theory and elastoplastic constitutive model, a multi-physical field coupling model of wave–vibration–seabed–monopile is constructed, and the dynamic characteristics of seabed pore pressure around the monopile under the joint action of wave–vibration are systematically investigated, and the influences of waves, vibrations, and seabed parameters on the distribution of pore pressure amplitude are analysed in depth. The results show that the increase in wave incident energy will increase the seabed wave pressure, and the suction and pressure generated by pile vibration will change the soil force state; the coupling of waves and vibrations results in pile displacement difference, causing the seabed pore pressure dissipation depth dissimilarity, and the peak relative amplitude of pore pressure and the peak of vibration displacement are in a linear relationship; the wave parameters and seabed characteristics have a significant effect on the change in pore pressure amplitude distribution. Full article
(This article belongs to the Section Ocean Engineering)
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7 pages, 2358 KiB  
Proceeding Paper
Effect of FSW Parameters on Microstructure and Mechanical Properties of Dissimilar Aluminum Joints
by Jayakumar Krishnamoorthy, Saran Kumar Murugesan, Sanjuvigasini Nagappan and Sanjay Prakash Prithiviraj
Eng. Proc. 2025, 93(1), 12; https://doi.org/10.3390/engproc2025093012 - 2 Jul 2025
Viewed by 233
Abstract
Friction stir welding (FSW) is a novel welding technique that produces a solid-state weld by generating frictional heat and plastic deformation at the weld spot with a revolving, non-consumable welding tool. Despite processing a wide range of industrial materials, FSW has concentrated on [...] Read more.
Friction stir welding (FSW) is a novel welding technique that produces a solid-state weld by generating frictional heat and plastic deformation at the weld spot with a revolving, non-consumable welding tool. Despite processing a wide range of industrial materials, FSW has concentrated on welding aluminum and its alloys because of its high strength-to-weight ratio and uses in the shipbuilding, aerospace, and other fabrication industries. Important FSW process factors that determine the mechanical qualities of the weldment are the tool tilt angle, tool traverse feed, tool pin profile, tool rotational speed (TRS), tool traverse speed (TTS), tool pin profile (TPP), and shoulder plunge depth. Variations in the required process parameters cause defects, which lower the weld quality of FSWed aluminum alloys (AA). Therefore, keeping an eye on and managing the FSW process is crucial to preserving the caliber of the weld joints. The current study aims to investigate the changes in the mechanical characteristics and microstructure of the FSWed AA5052-H111 and AA6061-T6 joints. To perform the FSW experiments, we varied TRS, TTS, and TPP on plates that were 5 mm thick and had a butt joint structure. Following welding, the microstructure of the weld zones was examined to observe how the grains had changed. The joint’s tensile strength reached a maximum of 227 MPa for the square-shaped TPP, and the micro-Vickers hardness test results showed a maximum of 102 HV at the weld nugget zone (WNZ). Full article
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8 pages, 2125 KiB  
Proceeding Paper
Experimental Analysis of Tensile and Metallurgical Properties in Similar and Dissimilar Metal Joints
by T. Sathish, M. Selvam, K. A. Harish, D. Vijay, G. Harish and D. Yashwant
Eng. Proc. 2025, 93(1), 3; https://doi.org/10.3390/engproc2025093003 - 30 Jun 2025
Viewed by 215
Abstract
This paper delves incto the tungsten inert gas (TIG) welding process, renowned for its efficacy in creating robust metal joints and widely employed in diverse industries for fusing similar or dissimilar materials. The focus of this study is the welding of mild steel [...] Read more.
This paper delves incto the tungsten inert gas (TIG) welding process, renowned for its efficacy in creating robust metal joints and widely employed in diverse industries for fusing similar or dissimilar materials. The focus of this study is the welding of mild steel with stainless steel, showcasing the method’s ability to amalgamate exceptionally sturdy metals and alloys. The resultant welded joints exhibit a meticulously refined microstructure and an impressive strength-to-weight ratio. The primary aim is to scrutinize TIG-welded joints, specifically those connecting mild steel with stainless steel, to elucidate their metallurgical and mechanical attributes. Notably, joints formed between distinct materials, such as mild steel and stainless steel, manifest commendable mechanical and metallurgical properties. This paper extensively investigates the metallurgical microstructures and tensile characteristics of both comparable and dissimilar metal junctions, contributing valuable insights to the field. Full article
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15 pages, 5614 KiB  
Article
Influence of Post-Heat Treatment on the Tensile Strength and Microstructure of Metal Inert Gas Dissimilar Welded Joints
by Van-Thuc Nguyen, Thanh Tan Nguyen, Van Huong Hoang, Tran Ngoc Thien, Duong Thi Kim Yen, Tri Ho Minh, Le Minh Tuan, Anh Tu Nguyen, Hoang Trong Nghia, Pham Quan Anh, Phan Quoc Bao and Van Thanh Tien Nguyen
Crystals 2025, 15(7), 586; https://doi.org/10.3390/cryst15070586 - 20 Jun 2025
Viewed by 334
Abstract
Taguchi and post-heat treatment methods have been used in this study to optimize the metal inert gas (MIG) welding joints between SUS304 austenite stainless steel and plain carbon SS400 steel using AWS ER 308L filler wire. The dissimilar welding joints’ microstructure and tensile [...] Read more.
Taguchi and post-heat treatment methods have been used in this study to optimize the metal inert gas (MIG) welding joints between SUS304 austenite stainless steel and plain carbon SS400 steel using AWS ER 308L filler wire. The dissimilar welding joints’ microstructure and tensile strength have been examined. The findings show that the fast cooling of the weld joint and the ferrite-forming element of the filler wire cause the dendrites’ δ-ferrite phase to emerge on both the weld bead and the heat-affected zone (HAZ) of the SUS304 side. The stickout parameter has the largest impact on the ultimate tensile strength (UTS), next to the welding speed, welding voltage, and welding current, due to the strong impact of the heat distribution. The optimal welding parameters are a welding current of 105 A, a welding voltage of 14.5 V, a stickout of 12 mm, and a welding speed of 420 mm/min, producing the UTS value of 445.3 MPa, which is close to the predicted value of 469.2 ± 53.6 MPa. Post-heat treatment with an annealing temperature that is lower than 700 °C could improve the optimized weld joints’ strength by up to 5%. The findings may provide a more realistic understanding of the dissimilar welding technology. Full article
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12 pages, 3830 KiB  
Article
Microstructural Features and Mechanical Properties of Laser–MIG Hybrid Welded–Brazed Ti/Al Butt Joints with Different Filler Wires
by Xin Zhao, Zhibin Yang, Yonghao Huang, Hongjun Zhu and Shaozheng Dong
Metals 2025, 15(6), 674; https://doi.org/10.3390/met15060674 - 17 Jun 2025
Viewed by 375
Abstract
Laser–MIG hybrid welding–brazing was performed to join TC4 titanium alloy and 5083 aluminum alloy with ER5356, ER4043 and ER2319 filler wires. The effects of the different filler wires on the microstructural features and mechanical properties of Ti/Al welded–brazed butt joints were investigated in [...] Read more.
Laser–MIG hybrid welding–brazing was performed to join TC4 titanium alloy and 5083 aluminum alloy with ER5356, ER4043 and ER2319 filler wires. The effects of the different filler wires on the microstructural features and mechanical properties of Ti/Al welded–brazed butt joints were investigated in detail. The wetting and spreading effect of the ER4043 filler wire was the best, especially on the weld’s rear surface. Serrated-shaped and rod-like IMCs were generated at the top region of the interface of the joint with ER4043 filler wire, but rod-like IMCs did not appear at the joints with the other filler wires. Only serrated-shaped IMCs appeared in the middle and bottom regions for the three filler wires. The phase compositions of all the IMCs were inferred as being made up of TiAl3. The average thickness of the IMC layer of joints with the ER5356 and ER2319 filler wires was almost the same and thinner than that of the joint with the ER4043 filler wire. The average thickness was largest in the middle region and smallest in the bottom region for all the joints with the three filler wires. The average microhardness in the weld metal of ER5356, ER4043 and ER2319 filler wires could reach up to 77.7 HV, 91.2 HV and 85.4 HV, respectively. The average tensile strength of joints with the ER5356, ER4043 and ER2319 filler wires was 106 MPa, 238 MPa and 192 MPa, respectively. The tensile samples all fractured at the IMC interface and showed a mixed brittle–ductile fracture feature. These research results could help confirm the appropriate filler wire for the laser–MIG hybrid welding–brazing of Ti/Al dissimilar butt joints. Full article
(This article belongs to the Special Issue Laser Processing Technology for Metals)
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18 pages, 7058 KiB  
Article
In-Depth Thermal Analysis of Different Pin Configurations in Friction Stir Spot Welding of Similar and Dissimilar Alloys
by Sajad N. Alasdi and Raheem Al-Sabur
J. Manuf. Mater. Process. 2025, 9(6), 184; https://doi.org/10.3390/jmmp9060184 - 1 Jun 2025
Viewed by 639
Abstract
Over the past decade, friction stir spot welding (FSSW) has gained increasing attention, making it a competitor to conventional welding methods such as resistance welding, rivets, and screws. This type of welding is environmentally friendly because it does not require welding tools and [...] Read more.
Over the past decade, friction stir spot welding (FSSW) has gained increasing attention, making it a competitor to conventional welding methods such as resistance welding, rivets, and screws. This type of welding is environmentally friendly because it does not require welding tools and is solid-state welding. This study attempts to demonstrate the importance of pin geometry on temperature distribution and joint quality by using threaded and non-threaded pins for similar and dissimilar alloys. To this end, thermal analysis of the welded joints was conducted using real-time monitoring from a thermal camera and an infrared thermometer, in addition to finite element method (FEM) simulations. The thermal analysis showed that the generated temperatures were higher in dissimilar alloys (Al-Cu) than in similar ones (Al-Al), reaching about 350 °C. In addition, dissimilar alloys show more pronounced FSSW stages through extended periods for each plunging, dwelling, and drawing-out time. The FEM simulation results are consistent with those obtained from thermal imaging cameras and infrared thermometers. The dwelling time was influential, as the higher it was, the more heat was generated, which could be close to the melting point, especially in aluminum alloys. This study provides an in-depth experimental and numerical investigation of temperature distribution throughout the welding cycle, utilizing different pin geometries for both similar and dissimilar non-ferrous alloy joints, offering valuable insights for advanced industrial welding applications. Full article
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26 pages, 85427 KiB  
Article
Analysis of the Effects of Tandem Welding (Fronius TPS/i - TWIN) of S1100QL and S1300QL Steels
by Mateusz Karczewski, Krzysztof Mroczka, Sławomir Parzych, Piotr Bała, Grzegorz Cios, Janusz Mikuła and Grzegorz Jeż
Materials 2025, 18(11), 2577; https://doi.org/10.3390/ma18112577 - 31 May 2025
Viewed by 545
Abstract
S1100QL and S1300QL steels are classified as fine-grained steels with a low-carbon martensitic structure. Tandem welding is a method of creating a joint by melting two electrode wires in a one-behind-the-other configuration. This article presents the effects of creating dissimilar joints, elements of [...] Read more.
S1100QL and S1300QL steels are classified as fine-grained steels with a low-carbon martensitic structure. Tandem welding is a method of creating a joint by melting two electrode wires in a one-behind-the-other configuration. This article presents the effects of creating dissimilar joints, elements of varying thicknesses made from S1100QL and S1300QL steels. The analysis focused on temperature changes in the heat-affected zone (HAZ) during welding, as well as the macro and microstructure, and the properties of the joints created at welding speeds of 80, 90, and 100 cm/min. The shortest cooling time (t8/5) in the HAZ for S1300QL steel was 9.4 s, while the longest was 12.4 s. Thermal cycle simulations were performed for the analyzed materials, with a cooling time of 5 s. The test results demonstrated that TWIN welding was stable, and an optimum welding speed is 80 cm/min. The HAZ microstructure for the highest cooling speed (t8/5 = 5 s) of S1100QL steel contains, in addition to martensite, lower bainite, while S1300QL steel consists of martensite. Tempered martensite was also detected at slower cooling rates. For all speed variants, the impact energy is above 27 J at a test temperature of −40 °C. In turn, hardness tests showed that the base material for both steels has the highest hardness. However, the lowest hardness was found for the weld. Full article
(This article belongs to the Section Manufacturing Processes and Systems)
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13 pages, 3086 KiB  
Article
Laser-MIG Hybrid Welding–Brazing Characteristics of Ti/Al Butt Joints with Different Groove Shapes
by Xin Zhao, Zhibin Yang, Yonghao Huang, Taixu Qu, Rui Cheng and Haiting Lv
Metals 2025, 15(6), 625; https://doi.org/10.3390/met15060625 - 31 May 2025
Viewed by 376
Abstract
TC4 titanium alloy and 5083 aluminum alloy with different groove shapes were joined by laser-MIG hybrid welding–brazing using ER4043 filler wire. The effects of groove shape on the weld formation, intermetallic compounds and tensile property of the Ti/Al butt joints were investigated. The [...] Read more.
TC4 titanium alloy and 5083 aluminum alloy with different groove shapes were joined by laser-MIG hybrid welding–brazing using ER4043 filler wire. The effects of groove shape on the weld formation, intermetallic compounds and tensile property of the Ti/Al butt joints were investigated. The welds without obvious defects could be obtained with grooves of I-shape and V-shape on Ti side, while welds quality with grooves of V-shape on Al side and V-shape on both sides were slightly worse. The interfacial intermetallic compounds (IMCs) on the brazing interface were homogeneous in the joints with groove of V-shape on Ti side, and V-shape on both sides, which had similar thickness and were both composed of TiAl3. Unlike the IMCs mainly composed of TiAl3 at the I-shape groove interface, TiAl3, TiAl, and Ti3Al constituted the IMCs at the V-shape on Al side interface. The average tensile strength of Ti/Al joints with groove of I-shape was the highest at 238 MPa, and was lowest at 140 MPa with groove of V-shape on Al side. The tensile samples mainly fractured at IMCs interface and the fractured surfaces all exhibited mixed brittle–ductile fracture mode. Based on the above research results, I-shape groove was recommended for laser-arc hybrid welding–brazing of 4 mm thick Ti/Al dissimilar butt joints. Full article
(This article belongs to the Special Issue Advances in Laser Processing of Metals and Alloys)
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31 pages, 7884 KiB  
Article
Magnetic Pulse Welding of Dissimilar Materials: Weldability Window for AA6082-T6/HC420LA Stacks
by Mario A. Renderos Cartagena, Edurne Iriondo Plaza, Amaia Torregaray Larruscain, Marie B. Touzet-Cortina and Franck A. Girot Mata
Metals 2025, 15(6), 619; https://doi.org/10.3390/met15060619 - 30 May 2025
Viewed by 654
Abstract
Magnetic pulse welding (MPW) is a promising solid-state joining process that utilizes electromagnetic forces to create high-speed, impact-like collisions between two metal components. This welding technique is widely known for its ability to join dissimilar metals, including aluminum, steel, and copper, without the [...] Read more.
Magnetic pulse welding (MPW) is a promising solid-state joining process that utilizes electromagnetic forces to create high-speed, impact-like collisions between two metal components. This welding technique is widely known for its ability to join dissimilar metals, including aluminum, steel, and copper, without the need for additional filler materials or fluxes. MPW offers several advantages, such as minimal heat input, no distortion or warping, and excellent joint strength and integrity. The process is highly efficient, with welding times typically ranging from microseconds to milliseconds, making it suitable for high-volume production applications in sectors including automotive, aerospace, electronics, and various other industries where strong and reliable joints are required. It provides a cost-effective solution for joining lightweight materials, reducing weight and improving fuel efficiency in transportation systems. This contribution concerns an application for the automotive sector (body-in-white) and specifically examines the welding of AA6082-T6 aluminum alloy with HC420LA cold-rolled micro-alloyed steel. One of the main aspects for MPW optimization is the determination of the process window that does not depend on the equipment used but rather on the parameters associated with the physical mechanisms of the process. It was demonstrated that process windows based on contact angle versus output voltage diagrams can be of interest for production use for a given component (shock absorbers, suspension struts, chassis components, instrument panel beams, next-generation crash boxes, etc.). The process window based on impact pressures versus impact velocity for different impact angles, in addition to not depending on the equipment, allows highlighting other factors such as the pressure welding threshold for different temperatures in the impact zone, critical transition speeds for straight or wavy interface formation, and the jetting/no jetting effect transition. Experimental results demonstrated that optimal welding conditions are achieved with impact velocities between 900 and 1200 m/s, impact pressures of 3000–4000 MPa, and impact angles ranging from 18–35°. These conditions correspond to optimal technological parameters including gaps of 1.5–2 mm and output voltages between 7.5 and 8.5 kV. Successful welds require mean energy values above 20 kJ and weld specific energy values exceeding 150 kJ/m2. The study establishes critical failure thresholds: welds consistently failed when gap distances exceeded 3 mm, output voltage dropped below 5.5 kV, or impact pressures fell below 2000 MPa. To determine these impact parameters, relationships based on Buckingham’s π theorem provide a viable solution closely aligned with experimental reality. Additionally, shear tests were conducted to determine weld cohesion, enabling the integration of mechanical resistance isovalues into the process window. The findings reveal an inverse relationship between impact angle and weld specific energy, with higher impact velocities producing thicker intermetallic compounds (IMCs), emphasizing the need for careful parameter optimization to balance weld strength and IMC formation. Full article
(This article belongs to the Topic Welding Experiment and Simulation)
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