The range of available aluminum alloy powders for laser powder bed fusion (LPBF) is restricted to mainly Al–Si based alloys. Currently aluminum alloy powders, designed for lightweight application, based on Al–Mg (5000 series), Al–Si...
There are still internal defects such as triangular zone cracks, centerline cracks, and intermediate cracks in 65Mn-Cr steel during the production process, which mostly occur in the initial solidification. In order to explore the evolution of interme...
The crack-free welding of aluminum alloy is very significant in manufacturing lightweight components since aluminum alloys are susceptible to solidification cracking during welding. This work reviews the current understanding and advancements in the...
In welding, liquation cracking can occur in the partially melted zone, leaving open cracks along the edge of the weld bead. Likewise, solidification cracking can occur in the mushy zone, leaving open cracks inside the weld bead (which is called the w...
Solidification cracking and liquation cracking have been reported frequently in additive manufacturing (AM) as well as welding. In the vast majority of weldability tests, a single-pass, single-layer weld is tested, though multiple-pass, multiple-laye...
A new test method named “Trapezoidal hot” cracking test was developed to evaluate solidification cracking susceptibility of stainless steel during laser welding. The new test method was used to obtain the solidification cracking directly,...
The average steepness of |dT/d(fs)1/2| on the T − (fs)1/2 curve were calculated during peritectic solidification, which was used to investigate the effect of alloying elements on surface longitudinal cracks of peritectic steels in the solidific...
High entropy CoCrFeNiCux alloys with a Cu molar ratio of x ≈ 0, 0.5, 1, 1.5 and 2 were arc welded. Solidification cracking occurred in the fusion zones of alloys with x ≈ 0.5, 1 and 1.5. Cu-rich material was observed around cracks, increa...
Cracking is a major problem for several types of steels during additive manufacturing. Non-equilibrium kinetics of rapid solidification and solid–solid phase transformations are critical in determining the cracking susceptibility. Previous studies co...
The addition of rare earth element Ce in ferritic stainless steel can improve the high temperature performance to meet the service requirements of automobile exhaust systems at high temperatures. Automobile exhaust systems are generally applied as we...
High-strength steel suffers from an increasing susceptibility to solidification cracking in welding due to increasing carbon equivalents. However, the cracking mechanism is not fully clear for a confidently completely crack-free welding process. To p...
In this work, a welding solidification crack sensitivity test platform was established to study the effect of wire feeding speed (WFS) on solidification crack sensitivity during cold metal transfer (CMT) welding for AA6061 aluminum alloy. The test re...
One of the main factors affecting the use of lasers in the industry for welding thick structures is the process accompanying solidification cracks. These cracks mostly occurring along the welding direction in the welding center, and strongly affect t...
Cracking during solidification is a complex phenomenon which has been investigated from various angles for decades using both experimental and theoretical methods. In this paper, cracking susceptibility was investigated by a simulation method for thr...
Oscillating laser beam welding for Al 6014 alloy was performed using a single mode fiber laser and two-axis scanner system. Its effect on the microstructural evolution of the fusion zone was investigated. To evaluate the influence of oscillation para...
Solidification cracking is a major obstacle when joining dissimilar alloys using additive manufacturing. In this work, location-specific solidification cracking susceptibility has been investigated using an integrated computational materials engineer...
Susceptibility to weld solidification cracking in transformation-induced plasticity steel sheets was studied using a modified standard hot cracking test used in the automotive industry. To vary the amount of self-restraint, bead-on-plate laser weldin...
The solidification cracking behavior in laser welds of steel/copper dissimilar metals was systematically investigated. T2 copper and SUS304 stainless steel were used in the study. The results showed that the occurrence of solidification cracking in w...
AA7075 is considered a ‘non-weldable’ alloy using fusion welding methods. In this study, laser welding is applied in pulse mode to weld 2 mm thick AA7075 aluminum alloy plates using different fillers. The aim is to identify the influence...
Solidification cracking is a critical defect in Cu–steel dissimilar laser welding for cylindrical lithium-ion battery busbar assembly, yet the metallurgical role of phosphorus (P) in crack formation has not been quantitatively established. In t...
This study investigates the effect of Gas Metal Arc Welding (GMAW) parameters on solidification cracking and mechanical behavior of AA6061 and AA7075 aluminum alloys, which are widely used in automotive, aerospace, and battery-related applications du...
In this study, 310S austenitic stainless-steel was welded using a laser with varying amounts of Nb to systematically investigate the effect of Nb on solidification cracking susceptibility, mechanical properties, and corrosion resistance of the weld....
Aiming to solve the persistent problem of edge cracking in magnesium alloy cast-rolling, this numerical simulation study introduces an innovative magnetic field-assisted approach. Utilizing Lorentz force, the process dynamically transforms the solidi...
Maraging steels hardened by Cu + NiAl precipitation have recently garnered attention owing to their relatively low cost and exceptionally high strength. However, the high alloy content can cause issues such as solidification cracking, particularly in...
Aluminum alloy 7075 (with 7055 and 7150 filler wires) was welded using a digital welding machine that can switch arc mode between MIG, CMT and CMT+P modes. The transverse-motion weldability test of joints welded under different arc modes showed that...
Recent years have witnessed increasing demand for selective laser melting (SLM) in practical applications; however, determining the appropriate process parameter range remains challenging. In this study, a framework was developed to determine the app...
The strain field can reflect the initiation time of solidification cracks during the welding process. The traditional strain measurement is to first obtain the displacement field through digital image correlation (DIC) or optical flow and then calcul...
To prevent the contamination of the marine environment caused by ship exhaust gas, the demand for LNG (liquefied natural gas) fueled ships is increasing worldwide. A tank to store LNG at cryogenic temperatures is indispensable to such LNG-fueled ship...
The environment of the global shipbuilding market is changing rapidly. Recently, the International Maritime Organization (IMO) has tightened regulations on sulfur oxide content standards for marine fuels and tightened sulfur oxide emission standards...
Integration of models that capture the complex physics of solidification on the macro and microstructural scale with the flexibility to consider multicomponent materials systems is a significant challenge in modeling additive manufacturing processes....
Aluminum alloy welding suffers from problems such as solidification cracking and hydrogen-induced porosity, which are sufficiently severe to limit its potential applications. Because mitigated porosity incidence and solidification cracking are observ...
High-strength aluminium alloy powders modified with different nanoparticles by ball milling (7075/TiC, 2024/CaB6, 6061/YSZ) have been investigated in-situ during rapid solidification by differential fast scanning calorimetry (DFSC). Solidification un...
Nickel is used in aerospace, military, energy, and chemical sectors. Commercially pure (CP) Ni, and its alloys, including solid-solution strengthened (SSS), precipitation strengthened (PS), and specialty alloys (SA), are widely utilized, typically at...
This article investigates the formation of solidification cracks in steel forgings used for bearing rings in gear reducers of robotic arms. The forging and heat treatment processes, conducted under consistent technological conditions, revealed the oc...
Inconel 738LC (IN738LC) is a nickel-based superalloy specially used in the hot section components of turbine engines. One of its main drawbacks relies on the cracking susceptibility when it is manufactured by laser powder bed fusion (LPBF). This pape...
During the welding of 690 nickel-based alloy, solidification cracking (SFC) and ductility-dip cracking (DDC) easily forms, which has a negative effect on the quality of welded joints and service life. The present study examined the effects of welding...
Understanding the mechanisms of microstructure evolution and defect formation, and their influence on mechanical properties and fracture mechanisms (from crack initiation to failure stage), is essential for manufacturing high-strength, fatigue-resist...
The present study aimed to investigate the increasing solidification rate during directional solidification developed from in situ composites of M7C3/austenite eutectic, to in situ composites with a small portion of dendrites, and to partial in situ...
Research into the processability of NiTiHf high-temperature shape memory alloys (HTSMAs) via laser powder bed fusion (LPBF) is limited; nevertheless, these alloys show promise for applications in extreme environments. This study aims to address this...
Powder Bed Fusion with Laser Beam of Metals (PBF-LB/M) is one of the fastest growing technology branches. More and more metallic alloys are being qualified, but processing of aluminum wrought alloys without cracks and defects is still challenging. It...
A model to predict the conditions for printability is presented. The model focuses on crack prevention, as well as on avoiding the formation of defects such as keyholes, balls and lack of fusion. Crack prevention is ensured by controlling the solidif...
Considerable research has been carried out to study the laser welding of magnesium alloys. However, the studies are mainly devoted to butt welding, and there has been limited information in the published literature concerning the bead-on-plate laser...
A novel chamfered mold is developed to solve the problem of corner transverse cracking in micro-alloyed steel slabs. The shape of the slab was changed from four corners and sides to eight corners and sides due to the use of a chamfered mold. Based on...
As the most commercially developed metal additive process, laser powder bed fusion (LPBF) is vital to advancing several industry sectors, enabling high-precision part production across aerospace, biomedical, and manufacturing industries. Al 7075 allo...
The main obstacle for the application of high strength 7××× series aluminum alloys is that these alloys are susceptible to hot cracking during fusion welding. This study presents the liquation cracking susceptibility of the novel T-...
The hot cracking behaviors of Mg-5Zn-xEr (x = 0.83, 1.25, 2.5, 5 wt.%) alloys are investigated by optimized hot cracking experimental apparatus, optical microscope, and scanning electron microscope, such as contraction behaviors, feeding behaviors, a...
This investigation attempts to explore the weld characteristics of a laser welded dissimilar joint of ferritic/martensitic 9Cr-1Mo-V-Nb (P91) steel and Incoloy 800HT austenitic nickel alloy. This dissimilar joint is essential in power generating nucl...
6063 aluminum alloy has broad application prospects in aerospace and microelectronic thermal management systems due to its good thermal conductivity and moderate strength. However, its extremely high hot cracking susceptibility during the laser powde...
AlZnMgCu, the high-strength aluminum alloy, is unsuitable for laser melting applications due to its high hot cracking sensitivity and large solidification temperature range. Adapting this alloy for laser melting processing is a high-demand research i...
One of the concepts behind Generation IV reactors is a molten salt coolant system, where the materials for the reactor itself and for the primary and secondary circuit components are subjected to extreme chemical and thermal stresses. Due to the unav...
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