This paper presents a novel approach of welding thick steel plates that offers time and energy savings compared with conventional techniques. The combination of gas metal arc welding (GMAW) and hot-wire technology simplifies the joint configuration and enhances the process tolerance. In this study, a square butt joint was prepared with as-cut edges and a thickness of 15 mm. The relationship between the welding current and the deposition rate of solo GMAW showed limitations and low process tolerance. Increasing the welding current led to a larger deposited volume with unnecessary weld penetration. An independent deposition volume due to hot-wire insertion was used to improve process tolerance. This approach provided an additional volume without increasing the welding current and reduced unnecessary penetration. With optimized parameters, full-penetration single-pass welding was achieved. Compared with the formation of a typical single-v butt joint at a similar welding speed of 30 cm/min, the proposed process reduced the minimum arc time and power consumption by approximately 83% and 62%, respectively. Moreover, a single pass at a travel speed of 60 cm/min was achieved with approximately 91% and 81% less arc time and power consumption, respectively. In summary, the combined process simplifies the joint configuration, enables full-penetration single-pass welding, and reduces time and energy requirements.

The demand for efficient processes through a comprehensive understanding and optimization of welding conditions continues to grow in the manufacturing industry. This study involves heat-resistant 2.25 Cr-1 Mo V-groove steel welding using the square-waveform alternating cur-rent. Experiments were conducted to build the relationship between input variables—such as current, frequency, electrode negativity ratio, and welding speed—and process performance, such as penetration, bay area, deposition rate, melting efficiency, percentage dilution, flux–wire ratio, and heat input. The process was analyzed in light of the defect-free high-deposition weld groove weld, the sensitivity to process parameters, and the optimization and development of the process map. The study proposes an innovative approach to reducing the cost and time of optimizing the one-pass-each-layer V-groove welding process using bead-on-plate welds. Square waveform welding creates a metallurgical notch in the form of a bay at the fusion boundary that can be minimized by selecting appropriate welding conditions. The square waveform submerged arc welding is more sensitive towards changes in current and welding speed than the frequency and electrode negativity ratio; however, the electrode negativity ratio and frequency are minor but helpful parameters to achieve optimal results. The proximity of the planned and experimental results to within 3% confirms the validity of the proposed approach. The investigation shows that 90% of the maximum deposition rate is possible for one-pass-each-layer V-groove welds within heat input and weld width constraints.

Heat pumps are increasingly becoming a key solution in the quest for decarbonization, offering a significant advantage over traditional boilers due to their superior energy efficiency. Not only can heat pumps provide both heating and cooling, but they also achieve thermal efficiencies exceeding 500%, which can seem to defy conventional expectations. The outdoor unit of a heat pump consists of about twenty main components, one of which is a complex network of copper pipes and sheets welded to valves, connectors, and other fittings. This set involves over thirty welded joints, highlighting a significant opportunity for reducing manufacturing time through process optimization. Copper is a critical material extensively used in various applications due to its excellent thermal and electrical conductivity. However, these very properties make welding copper particularly challenging, especially when aiming to automate and streamline industrial processes. Traditionally, connecting copper pipes and fittings is done through brazing, yet, alternative methods such as LASER welding, electron beam welding, resistance welding, friction welding, and ultrasonic welding also exist. This study focuses on the ultrasonic welding of copper, aiming to identify the optimal parameters that maximize the mechanical strength of overlapping joints and ensure effective tube sealing. Experimental results showed that for copper sheets, the best outcomes were achieved with a welding time of 3 s and a pressure of 6 bar. For tube sealing, the optimal conditions were a welding time of 3 s and a pressure of 4 bar. For both scenarios, the same variables were used, retention time of 0.62 s, initial pressure of 2 bar, retention pressure of 2 bar and sonotrode rising pressure of 3 bar. The analysis reveals that ultrasonic welding of copper can achieve both robust mechanical strength and reliable sealing, making it a promising technique for industrial applications.

The aim of this paper is to at first evaluate the influence of three key parameters including weld current, weld time and electrode force on nugget diameter and tensile strength in resistance projection welding. Then, a 2-D axis-symmetric finite element model is developed to simulate the projection welding and predict the nugget diameter. Finally, the FEM results are compared to experimental data to verify the simulation model and simulated results. In the finite element model, the temperature-dependent material properties were taken into account.

A study about influence of heat input on welding defects in vertical upward welding position for dissimilar material and thickness using a new variation of TIG welding torch is done with support of advanced inspection methods SEM and EBSD. With vertical upward welding position, control heat input plays an important role to keep the weld stabilization without defects. On the other hand, TIG welding process using a conventional TIG torch (conventional TIG welding process) has low efficiency and it is difficult to control heat input with high accuracy. So, it is considered that using conventional TIG torch is still a challenge for welding thin plates. In this case, a new variation of TIG torch has been developed. This torch used a constricted nozzle to improve plasma arc characteristics. As a result, it can control efficiently the heat input to prevent the excessive or insufficiency for joining thin sheets. For evaluation of welding quality, advanced examination methods SEM and EBSD were applied to directly observe the welding defects. From the results, the formation mechanism of blowhole inside weld zone in case of welding dissimilar material and thickness was discussed. It is pointed out that when sufficient welding current, the change from weld zone to base metal is uniform, no welding defects such as blowhole was seen. However, in case of low welding current, the thinner base metal is insufficient fusion and the change between weld zone and base metal is not uniform. The blowhole was observed at SS400 material side.

An important surgical goal is to provide a first intention wound healing without trauma produced by sutures and for this aim in the past several methods have been tested. The aim of this preliminary ex vivo study is to demonstrate the capacity of a 1070 nm pulsed fiber laser to treat the dental fractures by dentine melting with the apposition of hydroxyapatite nanoparticles as filler. Only the specimens of the group b showed a real process of welding of the two parts, while specimens of groups a and c did not reach a complete welding process. Out of thirty freshly-extracted human third molars, decay-free, twenty-four cylinders of 5 mm thickness were obtained to perform the test. The device used was a 1070 nm Yb-doped pulsed fiber laser: this source has a maximum average output power of 20 W and a fixed pulse duration of 100 ns, while the repetition rate ranges from 20 kHz to 100 kHz. The samples were divided in three groups (a, b, c) of eight teeth and each specimen, with the two portions strictly placed side by side, was put inside the box and irradiated three times, the first and the second at 30 kW and the last at 10 kW power. The frequency was maintained at 20 kHz for all the tests as well as the speed of the beam at 10 mm/sec. The samples of the group a were irradiated without apposition, in the group b nanoparticles (<200 nm) of hydroxyapatite were put in the gap between the two portions while in the group c, a powder of hydroxyapatite was employed. Only the specimens of the group b showed a real process of welding of the two parts, while specimens of groups a and c did not reach a complete welding process.

The automation of welding processes requires the use of automated systems and equipment, in many cases industrial robotic systems, to carry out welding processes that previously required human intervention. Automation in the industry offers numerous advantages, such as increased efficiency and productivity, cost reduction, improved product quality, increased flexibility and safety, and greater adaptability of companies to market changes. The field of welding automation is currently undergoing a period of profound changes due to a combination of technological, regulatory, and economic factors worldwide. Nowadays, the most relevant aspect of the welding industry is to meet customer requirements by satisfying their needs. To achieve this, the automation of the welding process through sensors and control algorithms ensures the quality of the parts and prevents errors such as porosity, unfused areas, deformations, excessive heat, etc. This paper proposes an intelligent and adaptive system based on the measurement of welding joints using laser scanning and the subsequent analysis of the obtained point cloud to adapt the welding trajectories.

Welded structures are subjected to internal residual stress after manufacturing that may affect the structural strength and normally are associated with an increase on initial geometrical imperfections. This study presents a simplified method to generate an adequate representation of residual stresses on Finite Element models for structural analysis of thin-walled structures and other applications. The results obtained shown that the methodology proposed to introduce residual stresses is simple, accurate and efficient on the modulation of post-welding stresses and their pattern, thus it may be used for simulation of the thermal process.

The material flow dynamic and velocity distribution on the melted domain surface play a crucial role on the joint quality and formation of welding defects. In this study, authors investigated the effects of the low and high currents of plasma arc welding on the material flow and thermodynamics of molten pool and its relationship to the welding defects. The high-speed video camera (HSVC) was used to observe the convection of the melted domain and welded-joint appearance. Furthermore, to consider the Marangoni force activation, the temperature on the melted domain was measured by a thermal HSVC. The results revealed that the velocity distribution on the weld surface was higher than that inside the molten weld pool due to the difference of the massive density between the air and the steel. Moreover, in the case of low welding current (80A) the convection speed of molten was faster than that of the high welding current case (160A) owing to the difference of main driving forces direction and strength, which leading to undercut and humping defects on the weld surface and excessive convex (burn-through) defect at the bottom weld side, respectively. The medium welding current (120A) had two convection patterns with the main flow in backward direction, which resulted in better welding quality without defect. The interaction between the shear force and Marangoni force played a solid state on the convection and heat transportation processes in the plasma arc welding process.

There is an increase towards reducing the weight of structures through the use of aluminium alloys in different industries like aerospace, automotive, etc. This growing interest would lead towards using dissimilar aluminium alloys which would require welding. TIG and friction stir welding are the well-known techniques that are currently suitable for joining dissimilar aluminium alloys. The welding of dissimilar alloys has its own dynamics which impact on the quality of the weld. This then suggests that there should be a process which can be used to improve the dissimilar alloys welds post their production. Friction stir processing is viewed as one of the techniques that could be used to improve the mechanical properties of the material. This paper reports on the status and the advancement of FSW, TIG and FSP technique. It further looks at the variation use of FSP on TIG and FSW welded joints with the purpose of identifying the knowledge gap.

To fulfil a need of limitation automotive emissions the reduction of vehicle weight is widely recommended and achieved in many ways, both by the construction of individual elements of the vehicle, and by the selection of light materials including Al alloys. Connecting these elements with each other and with elements made of iron alloys can be realized, inter alia, by welding or stir welding. However, the quality of the welds obtained varies widely and depends on many design, operational and environmental factors. The present study focused on a review of various welding technics used to joint both similar and dissimilar Al alloys utilized in automotive industry, the effect of various process parameters on welds quality, and phenomena appeared in such welds..

In recent decades, many attempts have been made to automate the entire welding process, how-ever, there remain many non-automated welding operations that present a constant hazard to workers. This article presents an automated welding solution with collaborative robots, with this contribution, we intend to help companies in this sector increase productivity, improve quality, effectively reduce costs, and improve working conditions.

In laser joining of copper (Cu) and aluminum (Al) sheets, the Al sheet is widely chosen as the top surface for laser irradiation because of increased absorption of laser beam and lower melting temperature of Al in contrast to Cu. This research focus on welding from Cu side to Al sheet. The main objective of irradiating the laser beam from the copper side (Cu on top) is to exploit higher solubility of Al in Cu. A significantly lower laser power can be used with 515 nm laser in comparison to 1030 nm. In addition to low laser power, a stable welding is obtained with 515 nm. Because of this advantage, 515 nm is selected for the current research. By fusion of Cu and Al the two sheet metals are welded, with presence of beneficial Cu solid solution phase and Al+Al2Cu in the joint with the brittle phases intermixed between the ductile phase. Therefore the mixed composition strengthens the joint. However excessive mixing leads to formation of more detrimental phases and less ductile phases. Therefore optimum mixing must be maintained. Energy dispersive X-ray spectroscopy (EDS) analysis indicate that large amount of beneficial Cu solid solution and Al rich phases is formed in the strong joint. From the tensile shear test for a strong joint, fracture is obtained on the heat-affected zone (HAZ) of Al. Therefore the key for welding from copper side is to have optimum melt with beneficial phases like Cu and Al+ Al2Cu and the detrimental phases intermixed between the ductile phases

Keyhole laser beam welding (LBW) of stainless steel sheets with a gap in between is numerically simulated with a three-dimensional, transient multi-physical model for laser material processing. At first, the model’s ability to reproduce experimental results on a relatively coarse computational mesh within reasonable computing time, so as to serve as process optimization tool, is presented. An example of process optimization, where a given set of weld seam quality criteria is fulfilled by iteratively optimizing a secondary laser beam, is shown. The relatively coarse mesh, in combination with a good model calibration to the experimental conditions, allows for sufficiently fast simulations to use this approach for optimization tasks. Finally, using a finer spatial and temporal discretization, the dynamic processes in the vicinity of the keyhole leading to the formation of pores are investigated. The physical phenomena predicted by the simulation are coherent with experimental observations found in literature.

A multi-strand composite welding wire was applied to join high nitrogen austenitic stainless steel, and microstructures and mechanical properties were investigated. The electrical signals demonstrate that the welding process using a multi-strand composite welding wire is highly stable. The welded joints are composed of columnar austenite and dendritic ferrite and welded joints obtained under high heat input and cooling rate have a noticeable coarse-grained heat-affected zone and larger columnar austenite in weld seam. Compared with welded joints obtained under the high heat input and cooling rate, welded joints have the higher fractions of deformed grains, high angle grain boundaries, Schmid factor and the lower dislocation density under the low heat input and cooling rate, which indicate a lower tensile strength and higher yield strength. The rotated goss (G_RD) orientation of a thin plate and the cube (C) orientation of a thick plate are obvious after welding, but the S orientation at 65° sections of Euler’s space is weak. The δ-ferrite was studied based on the primary ferrite solidification mode. It is observed that low heat input and high cooing rate result in the increasing of δ-ferrite and high dislocation density was obtained in grain boundaries of δ-ferrite. M₂₃C₆ precipitates due to low cooling rate and heat input in weld seam and deteriorates the elongation of welded joints. The engineering stress-strain curves also show the low elongation and tensile strength of welded joints under low heat input and cooling rate, which is mainly caused by the high fraction of δ-ferrite and the precipitation of M₂₃C₆.

Shape memory alloys (SMA) are becoming a more important factor in actuation technology. Due to their unique features, they bring the potential to safe weight, installation space and reduce energy consumption. The system integration of the generally small diameter NiTi wires is an important cornerstone for the emerging technology. Crimping, a common method for the mechanical and electrical connection of SMA wires, has several drawbacks when it comes to miniaturization and high force outputs. For high force applications for example, multiple SMA wires in parallel are needed to keep actuation frequencies high, while scaling up the actuation force. To meet these challenges, the proposed study deals with the development of a resistance welding process for manufacturing NiTi wire bundles. The wires are welded to sheet metal substrate, resulting in promising functional properties and high joint strengths. The welding process benefits from low cost, easy to control parameters and good automation potential. A method for evaluating the resistance welding process parameters is presented. With these parameters in place, a manufacturing process for bundled wire actuators is discussed and implemented. The welded joints are examined by peel tests, microscopy, and fatigue experiments. The performance of the manufactured bundle actuators is demonstrated by comparison to a single wire with the same accumulated cross-sectional area.

The effect of defects and microstructure on mechanical properties of Ti-6Al-4V welds produced by tungsten inert gas welding, plasma arc welding, electron beam welding and laser beam welding was studied in the present work. The mechanical properties of the different weld types have been evaluated with respect to micro hardness, yield strength, ultimate tensile strength, ductility and fatigue at room temperature and at elevated temperature. Metallographic investigation was carried out to characterize the microstructures of different weld types and fractographic investigation to relate the effect of defects on fatigue performance. Electron and laser beam welding produced welds with finer microstructure, higher tensile ductility and better fatigue performance than tungsten inert gas welding and plasma arc welding. Large pores and pores located close to the specimen surface were found to be most detrimental to fatigue life.

In this investigation steel P355NH has been successfully cladded with Inconel 625 through the method of explosive welding. Explosively welded bimetal clad-plate was subjected to the two separated post weld heat treatment processes: stress relief annealing (at 620oC for 90 minutes) and normalizing (at 910oC for 30 minutes). In order to analyze the microstructure of the joint in the as-welded state and to investigate the influence of the post weld heat treatment on it, the light and scanning electron microscope observations and microhardness analysis have been performed. The examination of the diffusion zone microstructure has been performed by using the scanning transmission electron microscope. It was stated that obtained joint has characteristic wavy-shape geometry with the presence of the melted zones and severe deformed grains of both joined materials. Strain hardening of the materials in joint zone was established with microhardness analysis. In both of the heat treatments the changes in the grain structure have been observed. The normalizing heat treatment has the most significant impact on the microstructure of the joint as well as the concentration of the chemical elements in the joint zone. It was reported that due to normalizing the diffusion zone has been formed together with precipitates in the joint zone. The analysis of the diffusion zone images leads to the conclusion that the diffusion of alloying elements from Inconel 625 to steel P355NH takes place along the grain boundaries with additional formation of the voids in this area. The precipitates in Inconel 625 in the joint zone are two type of carbides – chromium-rich and molybdenum-rich. Scanning transmission electron microscope observation of the grain microstructure in the diffusion zone shows that this area consists of equiaxed grains (from the side of Inconel 625 alloy) and columnar grains (from the side of steel P355NH).

This study explores the use of remote ultrasound vibration to enhance welding strength. It examines the effects of 20 kHz, and 40 kHz High Power Ultrasound Transducers (HPUT) in contact and contactless modes during ultrasonic assistance laser welding. Employing shear tests and microscopy for assessment, the research evaluates ultrasound's impact on welding strength and identifies the optimal transducer. Theoretical and numerical analyses investigate vibration transmission into the welding area, particularly examining the vibration distribution and cavitation initiation within the molten pool area. Results indicate that ultrasound-assisted welding increases pull test performance, including the resistance force and strain, and improves microscopic structural integrity. Numerical simulations suggest that narrow-band vibration intensifies pressure in specific welding zones. Contactless ultrasound application also shows enhanced welding quality, offering a promising alternative to current methods. This work contributes to electric car technology by suggesting improvements in welding techniques for power battery systems.

Bobbin Tool Friction Stir Welding (BTFSW) is a variant of FSW process using the special two shoulder tool that forms the top and bottom weld surface. As such, a significant simplification of welding setup is achieved. One of the dominant parameters of BTFSW process is the interference between tool shoulder pinch gap and weld metal thickness. In this research, the influence of interference of the square pin tool with convex shoulders on process temperature, microstructure, tensile, impact and bend performance were studied, and appropriate correlations were devised. The base metal was aluminum-magnesium alloy, with the interference varied in the range of 0.1 to 0.5 mm. The worm defects and irregularities were found in all specimens except in specimen welded with 0.4 mm interference. Optimal interference of 0.4 mm resulted in the highest mechanical properties, which, in terms of tensile strength and reduction of area were similar to the base metal. Furthermore, impact strength was significantly higher, which was attributed to grain refinement effect in the nugget zone.

So far, scientific studies on high frequency welding (HF) have observed the three main parameters: anode current, welding time and pressure of upper electrode. Some authors have also observed and studied the welding frequency, the power, and the values of the dielectric constants of the materials or the angle of dielectric losses. Due to the complex effects that the parameters have on the quality of the welded joint, it is necessary to extend the research and study the mutual relationships between a large numbers of process parameters on the welded joint in order to achieve satisfactory strength of the welded joint. In this research, the number of considered parameters is increased to 17, each of which is relevant to the processes of HF welding, and their mathematical equations are presented. The research is carried out on a HF welding machine improved with a linear pneumatic actuator for lowering the upper electrode and regulating the compressive force, and a measuring machine with the appropriate measuring method for determining the breaking forces with a tension gage and performing the „T“ test is made. Numerous researches were carried out on the functional changes of the process parameters of the percentage share of the values of the coupling capacitor, the anode current and the welding time on the values of the breaking forces of the welded joints. Based on the conducted research, it was concluded that the optimization of the process parameters of HF machine must be performed before the welding process, which is determined by a certain amount of energy that must be introduced into the material. These parameters are the capacity of the output capacitor, i.e., the value of the electric current flowing through the material and the time for the development of the operating power to produce welded joints with a certain strength and quality of welded joints for a specific material used in the process.

Magnetic pulse welding (MPW) employs high pulsed magnetic field to accelerate parts against each other thus forming an impact joining. Single-turn tool coils and field-shapers (FS) used in MPW operate under the most demanding conditions: a magnetic field of 40-50 T with a period of tens of microseconds. For conventional copper and bronze coils intense thermo-mechanical stresses lead to rapid degradation of the working bore. This work is aimed to improve the efficiency of field-shapers and focused on development of 2- and 4-slit FS with nanocomposite Cu 18Nb wire brazed as FS inner current-carrying layer. The measured ratio of magnetic field to discharge current was 56.3 and 50.6 T/MA for 2- and 4-slit FS respectively. FEM calculations of magnetic field generation showed its 6-9% and 3% variation for 2- and 4-slit FS respectively. The results of copper tube compression have shown an ovality of 27% and 7% for 2- and 4-slit FS respectively. The measured deviation of weld joining length was 11% and 1.4% in 2- and 4-slit FS respectively. Compared to the previous experiments on the whole steel inductor, the novel FS showed significantly better results in terms of efficiency and homogeneity of the magnetic field.

Crystallization often occurs in the laser welding of amorphous alloys, reducing the amorphous alloys’ properties. So, it is necessary to simulate the temperature field curve of the welding area by computer and then determine the power and laser moving speed of laser welding. In this paper, the temperature field curve of Zr41.2Ti13.8Cu12.5Ni10Be22.5(Vit1) amorphous alloy in laser welding is obtained by finite element analysis. The continuous heating curve (CHT) of Vit1 is fitted by the Vogel-Fulcher-Tammann (VFT) equation and the Kissinger equation. If the temperature field curve intersects with the CHT curve, crystallization occurs. The experiment results show that the VFT equation can be used to predict the crystallization of Vit1 better in laser welding. The tem-perature and welding time are increased by using low welding speed. Therefore, the temperature of the weld zone cannot fall in time, resulting intersection of the temperature field curve and the CHT curve. So, crystallization can be avoided if the welding speed is controlled within a rea-sonable range, and the highest temperature is kept under the CHT curve.

Clinching is a manufacturing method of mechanical joining two or more materials without the use of heat or additional components. This process relies on high plastic deformation to create a secure bond. Clinching technology is widely used for joining various grades and thickness of materials. Especially in the automotive industry, clinching is an alternative to spot resistance welding. However, the load-bearing capacity of clinched joints is comparatively lower when compared to resistance spot welded joints. This research aimed to enhance the load-carrying capacity of clinched joints. Experimental tests were conducted on clinched joints with locally modified microstructures to optimize their placement within the joint. The microstructure distribution in the clinched joint region was analysed using light and scanning electron microscopy, as well as microhardness measurements. Two material grades, micro-alloyed steels HX420LAD+Z and dual-phase ferritic-martensitic steels HCT600X+Z, were tested. Each grade underwent five groups of ten samples, subject to identical experimental conditions of local heating by resistance spot welding (RSW) and clinching. The application of RSW to the clinched joint area resulted in increase of load-bearing capacity for both joined types of materials.

Abstract: The paper compares and analyses the effects of correctly and excessively executed heating cycles on flame straightening, far above the limits recommended by the steel manufacturer. The paperwork emphasizes the microstructural changes induced by overheating in the flame straightening process. Flame straightening is a flame heating process of metal constructions in which very limited areas of the construction are heated to the straightening temperature with the aim of inducing geometrical changes.The flame straightening process is used in most of metallic structure manufacturing companies. In many cases, it is not possible to carry out under economic conditions of metal structures without flame straightening.

Electrode degradation in continuous resistance spot welding process of BH 220 steel was evaluated by electrode life test, and weldability tests were conducted by geometry features measurement, mechanical property analysis, and electrode diameter measurement with 88 or 176 weld intervals. The analysis of weld geometry shows that the HAZ width, nugget diameter, and nugget area tend to decrease rapidly, while the nugget height tends to firstly increase with the weld repetitions till the welding heat input becomes too small to form the valid nugget. The peak load shows a rapid downward trend, while failure energy and maximum displacement slightly increase till the 176th weld and then decrease. The cavities and pores in the nugget mainly appear after the 176th spot weld. The electrode diameter increases during welding. The reason for the increase in electrode diameter may be that the contact area between the electrode and BH 220 steel sheets becomes smaller in the welding process, which causes the continuous sticking phenomenon between the electrode and the BH 220 steel sheets. In the absence of alloying, the edge of the electrode is geometrically deformed, while Cu-Zn-Fe alloying occurs in the area in contact with the BH 220 steel sheet.

In this paper, the effect of preheating on the mechanical properties and micro structure of similar friction stir welded AA6061 aluminum alloys sheets was investigated. Aluminum alloy 6061 sheets with a thickness of 5 mm and threaded cylindrical pins were used. Rotation and traverse speeds were 1200 rpm and 75 mm/min, respectively. The results of tensile tests performed on the welded samples showed that compared to the non-preheated samples, preheating had increased the strength and elongation of the joints by 58% and 46%, respectively. In the present study, during the welding process preheating cause emerged heat with lower slope from stir zone. This phenomenon may result in Increase the deformation resistance of material and consequently decrease of grain size. This grain refinement can improve the mechanical properties of welds. Accordingly, hardness and strength of the material will be increased.

When a railway vehicle moves on a curved rail, sliding contact occurs between the rail head side and wheel flange, which wears the wheel flange down. The thinned flange needs to be restored above the required minimum thickness for structural safety. In this study, a new process and welding wire for restoring worn-out railway wheels by submerged arc welding was developed. To characterize the properties of the restored wheel, dilatometric analysis of phase transformation, SEM/EDX analyses, hardness measurement, and residual stress measurement using the X-ray diffraction method were performed. Finally, wear tests with full-size wheel/rail specimens were carried out. It was confirmed that the weld metal was composed of bainitic microstructures as intended, and welding defects were not observed. The wear amount of the restored wheel was greater than that of the base material, but it was less than half of the wear depth of the weld-repaired wheel with ferritic–pearlitic microstructures. The developed process seems applicable to industry.

Ensuring the quality of printed circuit boards (PCBs) in gas meters is essential to the reliable operation and safety of these devices. Traditional methods for detecting welding defects on PCBs, such as machine vision and deep learning, present significant limitations. Machine vision-based approaches lack the precision required in complex environments, while deep learning methods demand large, labeled datasets that are costly and impractical in industrial contexts. This paper introduces a novel melding defect detection method based on discrete optimal transport (DOT) theory, focused on identifying discrepancies in welding areas between sample and reference images. By limiting analysis to the welding regions, the proposed approach reduces computational costs associated with high-resolution image processing while maintaining detection precision and independence from large datasets. The DOT model calculates the optimal mass flow between images, pinpointing specific defects and providing actionable insights for defect tracing and repair, thereby overcoming the limitations of existing methods. Experimental results demonstrate that this approach is both effective and efficient, offering a robust solution for quality assurance in PCB manufacturing for gas meters.

One of the most important aspects in the fabrication of car seats is the quality of its welded joints. In this proposal, a design of experiments (DoE) approach is used to improve the actual process capability (Cpk) of weld penetration depth in automotive seat adjusters using a laser beam welding (LBW) machine TRUMPF TruDiode 3006. Welding speed effects, laser power, and focal position in the Z axis were considered to determine the optimal welding penetration depth conditions, which is a minimum of 1.20 mm in cold rolled steel metal sheets ZE 790 with a thickness of 1.60 mm. The initial process capability evaluation indicated a Cpk value of 0.50, considering the initial process parameters. The proposed design was modeled using the response surface methodology, stepwise reduction technique, F-test, and before and after process capability evaluation for validation purposes. After applying the proposed methodology, a Cpk of 1.81 was obtained, resulting in a significant improvement of the process, reducing defective parts from 6.51% to 0.00%.

Resistance spot welding is an established joining process in the production of safety-relevant components in the automotive industry. Therefore, a consecutive process monitoring is essential to meet the high-quality requirements. Artificial neural networks can be used to evaluate the process parameters and signals to ensure the individual spot weld quality. The predictive accuracy of such algorithms depends on the provided training data set and the prediction of untrained data is challenging. The aim of this paper is to investigate the extrapolation capability of the multi-layer perceptron model. That means, that the predictive performance of the model will be tested with data that clearly differs from the training data in terms of material and coating composition. Therefore, three multi-layer perceptron regression models were implemented to predict the nugget diameter from process data. The three models were able to predict the trained datasets very well. The models, which were provided with features from the dynamic resistance curve predicted the new dataset better than the model with only process parameters. This study shows the beneficial influence of the process signals on the predictive accuracy and robustness of artificial neural network algorithms. Especially, when predicting a data set from outside of the training space.

Nonwoven fabrics have been widely used in textile manufacturing industry as a sheet or web structure because of soft, water-repellent, recycle, ecological and resilient functions. Ultrasonic welding method has been applied for bonding nonwoven fabrics due to clean, fast and reliable approach. In this work, the ultrasonic stepped horn is designed to generate uniform amplitudes on the working surface by using finite element analysis (FEA) simulation. Chromium carbon steels are utilized to produce ultrasonic horns due to high wear resistant and hardness. Isotactic polypropylene nonwoven fabrics fabricated by spunbond process were bonded by continuous ultrasonic sewing machine. Ultrasonic horn with 70 mm in diameter working at 20 kHz, polypropylene (PP) nonwoven density of 80 gsm and various design of welding joints were applied. A typical image in the case of number one was investigated by the scanning electron microscope (SEM) images of inter-facial micro-structure. However, welding joints of totally eight roller patterns was test the tensile strength of the ultrasonic welding joints on PP nonwoven fabrics. The tensile strength of the welding joints is proportional to the area ratio between the welding area and cycling area. The results showed that the melted zone without welding defects such as crack or blowhole can be seen. Furthermore, the tensile strength of welding joints in eight cases of roller patterns (No.1-No.8) was described in details. The ultrasonic welding joints with brick structures give higher tensile strength while the solid line in the pattern gave less strength.

Aluminum alloy Al 2024-T3 were successfully joined using friction stir spot jwelding joining (FSSW). Satisfactory joint strengths were obtained at different welding parameters (tool rotational speed, tool plunge depth, dwell time) and tool pin profile (straight cylindrical, triangular and tapered cylindrical). Resulting joints were welded with welded zone. The different tools significantly influenced the evolution on the stir zone in the welds. Lap-shear tests were carried out to find the weld strength. Weld cross section appearance observations were also done. The macrostructure shows that the welding parameters have a determinant effect on the weld strength (x: the nugget thickness, y: the thickness of the upper sheet and SZ: stir zone). The main fracture mode was pull out fracture modes in the tensile shear test of joints. The results of tensile shear tests showed that the tensile-shear load increased with increasing rotational speed in the shoulder penetration depth of 0.2 mm. Failure joints were obrerved in the weld high shoulder penetration depth and insufficient tool rotation.

The aim of this investigation is to offer a data-based scheme for predicting electrode wear in resistance spot welding. Electrode wear and alloying is one of the most significant factors that affect the mechanical properties of spot welds and the variation in weld quality. In this study, Rogowski coils and twisted pairs attached to the top and bottom electrodes were used to obtain the welding current and the inter-electrode voltage in the welding process, thereby calculating the dynamic resistance value during the welding process. The electrode diameter was obtained from the pressure exerted by the upper and lower electrodes on the carbon paper when the current was cut off and was regarded as an indicator of electrode wear. By continuously welding 0.5mm thick BH 340 steel plates until the electrode failed, the dynamic resistance signal was recorded in real time. Simultaneously, the electrode diameter after every 4 welds was also recorded. On this basis, the correlation between electrode diameter and dynamic resistance is studied. In order to quantitatively study the mapping relationship between dynamic resistance and electrode wear, 11 characteristic values were extracted from the dynamic resistance, and the stepwise regression method was used to obtain the regression formula between the characteristic values and the electrode diameter. Using new data to verify the effectiveness of the regression model, the acquired results display that the maximum error between the predicted value of the electrode diameter and the measured value obtained by the regression equation with the interactive quadratic term is 0.3 mm, and the corresponding relative error is 7.69 %. This result demonstrates that the method proposed in this paper can effectively monitor the electrode wear and failure process.

The CMT (Cold Metal Transfer) arc welding process is a convenient instrument for the assembly of thin sheets [1], [2]. More particularly, it permits the decrease of the amount of heat transferred to the parts to-be assembled, thus reducing their subsequent deformations. The present work aims at simulating the CMT welding of thin stainless-steel sheets in order to develop an approach that allows the prediction of temperature fields, as well as final deformations induced by the welding process. For that purpose, instrumented tests and numerical simulations were set aiming at comparing the experiments with simulations. Butt-welding of stainless-steel sheets was considered, with a thickness ranging from 1 to 1.2 mm. The weld seam samples were observed in order to set an equivalent heat source for each configuration. Moreover, the electric current and voltage were surveyed, and temperature measurements were performed using K-type thermocouples. In addition, displacement measurements were obtained using the DIC (Digital Image Correlation) technique. Thermomechanical simulations were then carried out using an equivalent heat source approach, considering the phase changes of elements, i.e. the transitions from solid to liquid and from liquid to solid. These simulations also consider the actual geometry of seams induced by addition of a filler material.

The welding and construction processes of H-type thick-plate-bridge steel involve complex multi-pass welding processes, which is difficulty to ensure its welding performance. Accordingly, it is crucial to explore the inherent correlation among the welding processes parameters and welding quality, and applied it into the welding robots, eliminating the instability from manual welding. In order to improve the welding quality, the GMAW (Gas Metal Arc Welding) welding process parameters are simulated using the Q345qD bridge steel flat joint model. Four welds with X-shaped grooves are designed to optimize the parameters of welding current, welding voltage, and welding speed. The optimal welding process parameters are investigated through thermal-elastic-plastic simulation analysis and experimental verification. The results indicate that when the welding current is set to 230A, the welding voltage to 32V, and the welding speed to 0.003m/s, the maximum deformation of the welded plate is 0.52mm, with a maximum welding residual stress of 345MPa. Both the simulation results of multi-pass welding and experimental tests meet the welding requirements, as they show no excessive stress or strain. These parameters can be applied into building large steel frame bridges with welding robots, improving the quality of welded joints.

Welding processes offer a unique capability with a wide range of applications in industries. In recent times, welding has established itself as a tool for large scale additive manufacturing. In general, the quality and repeatability assurance for welding and specifically for additive manufacturing necessitates integrating process monitoring techniques with existing welding and additive manufacturing processes. The process-specific signals such as welding current fluctuations, temperature, and acoustic, generated during the welding operations, make them a suitable candidate for digitization. This chapter comprehensively describes the process monitoring techniques relevant to welding and additive manufacturing. Firstly, various sensors used during welding are described for their construction and working. Subsequently, specific applications of the sensors in digitizing the welding processes are presented.

The present study utilizes a metal inert gas welding (MIG) to make a dissimilar weld joint of different stainless steel grades AISI 304, 314, 316L, 420 and a standard structural steel S355MC to estimate the correlation of a microstructure and the mechanical properties. The microstructure of the base metals (BM), the heat affected zone (HAZ), the fusion zone (FZ) and the weld seam were analyzed using optical microscopy. Optical microscopy did not reveal any presence of weld defects such as porosity or cracks. The analysis of microstructure showed that both the austenitic and martensitic stainless steel weld structures contain some retained delta ferrite and coarse Me23C6 carbides in the HAZ, while the FZ exhibits delta ferrite and some retained austenite. The hardness profiles revealed difference between austenitic and martensitic steel welds that the later showed extremely high values in the HAZ (~500 HV/0.1) which causes fracture in this zone. The welds of all austenitic steel grades withstood tensile test, showing the average tensile strength of 472 MPa with fracture observed in the base metal zone. It made clear that the use of a filler rod 308LSI is suitable only for the austenitic stainless and structural steel dissimilar welds, and not appropriate for martensitic-structural steel welds. The achieved results revealed that the higher hardness of the martensitic phase in the HAZ of AISI 420 is closely related with the formation of untempered coarse martensitic structure and higher carbon content.

With the aim to investigate the effect of parameter and quenching process on the joint of hot stamping steel by laser welding, the BR1500HS boron steel was welded by filling-wire laser welding with ER70-G welding wire under different parameters. The welded specimens were heated to 900℃ and held for 5min before water quenching. The universal material test machine, Optical micro-scope, Vickers hardness tester, scanning electron microscope and electron backscatter diffraction (EBSD) were used to characterize. The results showed that the macroscopic morphology of fusion zone (FZ) becomes from funnelform to hyperbolic curve shape when heat input increases and from hyperbolic curve shape to funnelform when wire-feed speed increases. The strength after quenching is more than 1557Mpa at heat input of 1040J/cm, wire feeding speed of 1.6m/min~1.8m/min and welding speed of 1.5m/min. EBSD test showed that the FZ and fine grain zone (FGZ) have more retained austenite (RA) than coarse grain zone (CGZ) before quenching and RA in FZ and heat affect zone (HAZ) decreased and distributed uniformed after quenching. The grain diameter in FZ distribute unevenly, with the maximum grain diameter larger than 40μm before quenching. After quenching, the grain diameter of FZ, HAZ and BM is more even and coarse grains in the FZ was refined. Before quenching, the microhardness of FZ and HAZ is of 450HV~500HV at different heat input and wire-feed speed and all region of joint keeps at 450HV~550HV after quenching. Most dimple and little river pattern in the joint fracture mor-phology before quenching indicates a well plasticity and most cleavage facet is observed after quenching due to the joint combine with martensite.

Welding of dissimilar aluminium alloys has been a challenge for a long period until the discovery of the solid state welding technique called friction stir welding (FSW). The discovery of this technique encouraged different research interests revolving around the optimization of this technique. This involves the welding parameters optimization and this optimization is categorized into two classes i.e. similar alloys and dissimilar alloys. This paper reports about the mechanical properties of the friction stir welded dissimilar AA1050-H14 and AA5083-H111 joint. The main focus is to compare the mechanical properties of specimens extracted from different locations of the welds i.e. the beginning, middle and the end of the weld. The specimen extracted at the beginning of the weld showed low tensile properties compared to specimens extracted from different locations of the weld. There was no certain trend noted through the bending results. All three specimens showed dimpled fracture which is the characterization of the ductile fracture.

A numerical model was developed for predicting the bead geometry and microstructure in Laser Beam Welding of 2 mm thickness Inconel 718 sheets. The experiments were carried out with a 1 kW maximum power fiber laser coupled with a galvanometric scanner. Wobble strategy was employed for sweeping 1 mm wide circular areas for creating the weld seams and a specific tooling was manufactured for supplying protective Argon gas during the welding process. The numerical model takes into account both the laser beam absorption and the melt-pool fluid movement along the bead section, resulting in a weld geometry that depends on the process input parameters, such as feed rate and laser power. The microstructure of the beads was also estimated based on the cooling rate of the material. Features as bead upper and bottom final shapes, weld penetration and dendritic arm spacing were numerically and experimentally analyzed and discussed. The results given by the numerical analysis agree with the tests, making the model a robust predictive tool.

Among all the processing technologies of heat-treatable aluminum alloys like 2219 aluminum alloy, using friction stir welding (FSW) as the joining technology and using electromagnetic forming (EMF) for plastic forming technology both have obvious advantages and successful applications. Therefore, there is a broad prospect for the compound technologies which can be used on the 2219 aluminum alloy to manufacture the large-scale thin-wall parts in the astronautic industry. The microstructure and mechanical properties of 2219 aluminum alloy under the process compounded of FSW, heat treatment, and EMF were investigated by means of tensile test, optical microscope (OM), and scanning electron microscope (SEM). The results show that the reduction of strength, which was caused during the FSW process, can be recovered effectively by the post-welding heat treatment composed of solid solution and aging, while the ductility was still reduced after heat treatment. Under the compound technology of FSW, heat treatment, and EMF, the forming limit of 2219 aluminum alloy decreased distinctly due to the poor ductility of the welding joint. A ribbon-pattern, which was formed due to the banded structure caused by FSW process, was found on the fracture surface of welded 2219 aluminum alloy after EMF treatment. During the EMF process, because of the effects of induced eddy current, a unique structure, which was manifested as a molted-surface appearance under the SEM observation, was formed as the material fractured.

The article describes machine learning using artificial neural networks (ANN) to develop the parameters of the friction stir welding (FSW) process for three types of aluminum joints (EN AW 7075). A total of 608 experimental data were used to build the ANN. Two types of networks were built: the first one was used to classify good/bad connections with the MLP 7-19-2 topology, the second one was used to regress the tensile load-bearing capacity with the MLP 7-19-1 topology. Selected parameters of the FSW process were used as input data for ANN training: rotational speed, welding speed, joint and tool geometry. Based on a case study, the quality of the FSW joint was assessed in terms of microstructure and mechanical properties. The usefulness of both trained neural networks has been demonstrated. For the regression network, the quality of the validation set was approximately 93.6%. In the case of confusion matrix for the test set, errors never exceeded 6%. Only 184 epochs were needed to train the regression network. The quality of the validation set was approximately 87.1%. On their basis, predictive maps were developed and presented in the work allowing for the selection of optimal parameters of the FSW process for three types of joints.

Traditional methods of non-metallic materials joining for industrial uses are limited to lasers, or induction or conduction heating. The precision and efficiency for large-scale applications are difficult to be achieved at the same time. Here in this paper, we report a precise microwave welding method induced by localized surface plasmon of metallic macro-gaps under microwave excitation. The proposed method utilizes energy from well-developed commercial microwaver, and benefits from the precision of localized surface plasmon, an oscillating electron cloud excited by electromagnetic waves, which is currently under hot investigation only at micro- or nano-scales. The method is applied to the welding of polymers to solve the problems of complex processing equipment and high processing energy consumption in the traditional welding process, so as to cope with the growing energy and environmental crisis. Finite element numerical simulations are used to study the distribution characteristics of electric fields and temperature fields. The results show that the process is a high quality, efficient, low consumption and environmentally friendly green process compared to traditional polymer welding methods.

Keywords: Fatigue crack propagation; Welding residual stress; Plastic re-distribution; Stress ratio effect

This paper investigates the use of contactless power ultrasonic excitation to decrease the electrical impedance of the weld in laser welding. The literature extensively documents the impact of em-ploying contact power ultrasonic excitation on the microstructure morphology and refinement of grain in the weld. This study involves characterizing an industrial High Power Ultrasound Transducer (HPUT) by determining the optimal distance and angle for contactless excitation of the fusion zone in the weld, aiming to achieve the maximum amplitude. Subsequently, the transducer is integrated into the laser welding system, resulting in the creation of an ultrasonic-assisted welding system. To find the improvement due to the contactless vibration assistance, the welding area was char-acterised by an impedance ohmmeter device. The results indicate an approximately 6 % im-provement in the welding quality in terms of the impedance value, an important parameter for battery pack welding. In response to the issue of overheating in the industrial transducer during prolonged welding operations, an alternative transducer was proposed to overcome this challenge. Further investigations are carried out by the alternative transducer to find the effect of different wave types, namely, shear and compressional waves, on the welding quality. The contact vibration can excite the plate approximately 50 times higher in acceleration amplitude than contactless ex-citation. Nevertheless, enhancements of 10% and 6% are observed in the impedance value when utilising compressional and shear waves, respectively, as compared to the results obtained with contactless vibration.

This investigation aims to discuss the formation process of eddies and the heat transportation in plasma keyhole arc welding. In order to clarify this issue, the measurement of the convection inside the weld pool, the convection on the weld pool surface, also the temperature distribution on the weld pool surface were carried out. The results showed that two eddies were found in the weld pool, which is controlled mainly through the shear force by the plasma flow acting on the weld pool surface. The magnitude, extent and direction of the shear force are thought to be determined primarily by the variation of keyhole profile. The relative shape and strength of each eddy is largely changed depending on the change of the keyhole profile when nozzle diameter changed. These relative strengths of each eddy are considered to decisively govern the heat transport in the weld pool coinciding with the direction of eddies. A larger eddy near the lower part of the keyhole inside the weld pool was found out in the case of 1.6 mm, meanwhile a upward larger eddy was found out near the upper part of the keyhole inside the weld pool in the case of 2.4 mm.

The aim of this work is to assess the influence of Friction Stir Welding (FSW), process parameters, optimized tool traveling speed, and corrosion resistance of the 0.95 Mg-Al-alloy and pure copper weldment. Samples of aluminum-copper with and without deformation were characterized to investigate the metallurgical effects created during the welding deformation process. Effect of process parameters on microstructure and corrosion rate have been investigated for all the samples. All the electrochemical and polarization tests were done in 3.5 wt.% NaCl solution. Scanning Kelvin Probe (SKP) was done to detect the localized corrosion on the surface. Optical micrography observation indicated that the primary α-Al phase, which was formed during solidification can effectively limit the growth of Cu₉Al₄ phase. Finer acicular α-Al precipitates were observed in CuAl matrix during joining process that tends to coarser with the increase in tools travel speed. The electrochemical and polarization results showed that among all the tool travelling speed the specimen joined at tool travelling speed of 40 mm/min shows the best non-corrosive property.

The aim of this work was to investigate the microstructure and the mechanical properties of la-ser-welded joints combined of DP800 and DP1000 high strength thin steel sheets. The welded joints (WJ) comprised of similar/dissimilar steels with similar/dissimilar thickness were consisted of different zones and exhibited similar microstructural characteristics. The trend of microhard-ness for all WJs was consistent, characterized of the highest value at hardening zone (HZ) and lowest at softening zone (SZ). The degree of softening was more severe and the size of SZ was wider in the WJ combinations of DP1000 than DP800. The tensile test fractures were located at the base material (BM) for all DP800 weldments, while the fractures occurred at the fusion zone (FZ) for the weldments with DP1000 and those with dissimilar sheet thicknesses. The DP800-DP1000 weldment presented similar yield strength (YS) and ultimate tensile strength (UTS) values but lower elongation (EI) in comparison with the DP800-DP800 weldment, which showed similar strength properties as the BM of DP800. However, the EI of DP1000-DP1000 weldment was much lower in comparison with the BM of DP1000. The DP800-DP1000 weldment with dissimilar thicknesses showed the highest YS and UTS values compared with the other weldments, but with the lowest EI. The fatigue fractures occurred at the WJ for all types of weldments. The DP800-DP800 weldment had the highest fatigue limit and DP800-DP1000 with dissimilar thick-nesses had the lowest fatigue limit. The fatigue crack initiated from the weld surface.

Diffusion bonding is often used on pre-machined parts to generate internal cavities, e.g. for cooling injection molding tools close to the mold cavity. Only then, the workpieces are finished to their final dimensions. In the case of micro-process devices, however, it is essential to precisely control the deformation, as otherwise uncontrollable pressure losses will occur with channel cross-sections in the sub-millimeter range. Post-processing is not possible. The most important process parameters for diffusion bonding are temperature, dwell time and contact pressure, with the bonding temperature and contact pressure acting in opposite directions and showing a strong non-linear dependence on deformation. In addition, the deformation is influenced by a number of other factors such as the absolute size of the cross-section and the aspect ratio of the parts, the dimensions and distribution of the internal cross sections and the overall percentage of the cross-section to be bonded. In micro process engineering, small material cross-sections in the range of the materials microstructure can facilitate additional deformation mechanisms such as grain boundary sliding, which are not relevant at all for larger structures. For parts consisting of multiple layers, tolerances in thickness and roughness of multiple surfaces must be levelled, contributing to the percentaged deformation. This makes it difficult, especially in micro process engineering and in single or small series production, to determine suitable joining parameters in advance, which on the one hand do not cause unforeseen large deformations, but on the other hand reliably produce highly vacuum-tight components. Hence, a definition of a fixed percentaged deformation does not work for all kinds of components. This makes it difficult to specify parameters for surely obtain high-vacuum tight parts. For successful diffusion bonding, atoms must diffuse over the bonding planes, forming a monolithic part in which the original layers are no longer visible. Only then, mechanical properties identical to those of the base material, which has been subjected to identical heat treatment, can be achieved. In this paper, the impacts of different material cross section widths as well as of the aspect ratio on deformation were investigated. By accident, it was found that also accuracy of the temperature measurement may have a serious impact in terms of deformation.

At the beginning of any electric arc welding process, a regime called transient regime will always occur, characterized by the continuous variation of the energy flow, also resulting in the variation of the cooling rate of the welded joint. Consequently, the weld bead hardness varies from a maximum value to an approximately constant value, and this phenomenon can be represented by an asymptotic exponential function. For several welded specimens, it would be possible to fit a non-linear regression for each specimen, however, it would be a difficult task to combine different regressions in a single analysis. The objective of this study is to evaluate the applicability of mixed-effects models and artificial neural networks to predict the longitudinal hardness of the weld bead in the initial transient regime. To this end, linearized and nonlinear mixed-effects models and artificial neural networks with different architectures were fitted. Finally, valid models were obtained with all approaches, with artificial neural network model slightly better fitted. However, the explainability capacity of the linearized mixed-effects model was superior, showing that the relative thickness, one of the predictor variables, was responsible for 48% of the variation in longitudinal hardness of weld bead.

This study aimed to investigate the fatigue performance and interfacial strengthening mechanisms of Al6061-to-Cu dissimilar lap joints via electromagnetic pulse welding (EMPW). The load-bearing capacity of the joints at discharge voltages of 14 kV and 16 kV was superior to that of 12 kV. Furthermore, the fatigue life of the 14 kV joints was one order of magnitude higher compared to the 12 kV joints. SEM observation of the fatigue fracture surface revealed the presence of typical "tire-mark" fatigue striations only in the 14 kV joint, indicating higher ductility and the ability to withstand extended plastic deformation. Notably, ultra-fine nanocrystalline Al2Cu phase, amorphous phase, and numerous dislocations hindered EBSD acquisition in the transition zone. Nevertheless, dense low-angle grain boundaries (LAGBs) and refined grains were examined at the bonding interface. This suggests that the high-velocity collision caused severe plastic deformation and led to the formation of substructures. The interfacial strength was attributed not only to the "wave-like" or "inverted hook-like" diffusion layer but also to the presence of refined grains along the interface and nanocrystalline Al2Cu in the transition zone. Furthermore, the hybrid nanocrystalline-amorphous microstructure strengthened the joint by regulating the balance between strength and ductility.

This study investigated the fatigue properties and interfacial strengthening mechanisms of Al6061-to-Cu dissimilar welded joints via electromagnetic pulse welding (EMPW). The load-bearing capacity of the joints at discharge voltages of 14 kV and 16 kV was superior to that of 12 kV. Meanwhile, the fatigue life of 14 kV joints was one order of magnitude higher than that of 12 kV. The SEM observation on the fatigue fracture surface shows that the typical “tire-mark” fatigue striation just appeared on the 14 kV joint, indicating higher ductility for handling more extended plastic deformation. The high EBSD acquisition was achieved except for the transition zone due to the formation of ultra-fine nanocrystalline Al2Cu phase and amorphous phase, along with many dislocations. Dense low-angle grain boundaries (LAGBs) and refined grains are formed along the bonding interface. This indicates that severe plastic deformation induced dislocations to form the substructure in such an instant (40-60 μs) during the high-velocity collision. The interfacial strength is not only due to the continuous interfacial diffusion layer with a “wave-like” or “inverted hook-like” pattern but also benefits from refined grains along the interface and in the transition zone, as well as the hybrid amorphous-nanocrystalline microstructure, which strengthens the joint through increasing ductility induced by refined grains and regulating amorphous or nanocrystalline phases to affect the balance between strength and ductility of the Al/Cu joint.

Steel structures, such as bridges, must be continuously maintained. Due to increasing trac loads, design and execution shortcomings, many steel bridges are subject to various types of damage, such as cracks. The bridges must be maintained by crack removal and re-welding the cracks. During this work, the bridge is closed for trac in order to suppress the crack ank movement during welding. As a result, trac loads on other routes are higher, which increases further damage on detour routes and subsequently additional welding work and costs on theses structures. Therefore, the aim is to provide a method that allows welding work on steel structures under running trac, respectively under cyclic loads. First, measurements at a representative steel bridge were conducted to derive gap opening parameters of amplitude and frequency for welding tests under cyclic loads. In a test setup for reproducible and comparable welding tests, specimen were welded under cyclic loads. Deep grinding of the root layer allowed defect-free welding within the range of 0.1 mm amplitude at a frequency of 2 Hz loadings. For such welds, the weld quality and the fatigue strength was comparable to the standard requirements.

Employing numerical methods to simulate manufacturing processes and study their influential factors is increasing. The development of computers and engineering software has increased the ability and accuracy of numerical methods in simulating various aspects of different processes. One of the manufacturing processes that has been considered by many industries in recent years to join metals in solid-state with unique properties is called friction stir welding. It is challenging and, in some cases, impossible to experimentally study the various aspects of this process, such as temperature distribution, stress distribution, and material flow, due to severe plastic deformation in the weld zone. In this case, numerical methods are used to investigate these parameters and better understand the process. This study first investigates various numerical methods researchers use to simulate the process. The ability, pros, and cons of these methods to simulate the process are also examined. Then, the applications of numerical models in simulating the temperature distribution during the process as well as the effects of input parameters on the temperature history of the process, are deeply considered. Next, the application of numerical methods in material flow modeling during the process is investigated. Finally, the modeling of the microstructure of the welding zone is investigated using numerical methods that help significantly in predicting the weld microstructure.

Aiming to diminish the defects caused by high-speed pulsed GMAW welding, such as non-penetration, non-fusion, humping and undercut, the paper proposed an improved twin-wire double-pulsed high-speed welding process by introducing the impact of additional shielding gas on the welding pool and the effects of different shielding gas flowrates on the microstructure and mechanical properties of the welded seam was investigated. The 2205 duplex stainless steel plate was used as the base material for the butt welding test, and the welded seams were subjected to tensile test, metallographic analysis, hardness analysis, and nondestructive testing. The results indicate that as the flowrate of additional shielding gas increases in the range of 8 L/min~16 L/min, the width of the welded seam increases and the height of reinforcement decreases gradually. However, a grooved seam with a lower middle region and higher sides will appear when the gas flowrate becomes excessively large. The test results indicate that the jet impact force is relatively moderate when the flowrate of the additional shielding gas is 12 L/min and thus, is optimal for the welded seam.

In an industrial environment, the quality assurance of weld seams requires extensive efforts. The most commonly used methods for that are expensive and time-consuming destructive tests, since quality assurance procedures are difficult to integrate into production processes. Beyond that, available test methods allow only the assessment of a very limited set of characteristics. They are either suitable for determining selected geometric features or for locating and evaluating internal seam defects. The presented work describes an evaluation methodology based on microfocus X-ray computed tomography scans (µCT scans) which enable the 3D characterization of weld seams, including internal defects such as cracks and pores. A 3D representation of the weld contour, i.e., the complete geometry of the joint area in the component with all quality-relevant geometric criteria, is an unprecedented novelty. Both the dimensions of the weld seam and internal defects can be revealed, quantified with a resolution down to a few micrometers and precisely assigned to the welded component. On the basis of the methodology developed within the framework of this study, the results of the scans performed on the alloy AA 2219 can be transferred to other aluminum alloys. In this way, the data evaluation framework can be used to obtain extensive reference data for the calibration and validation of inline process monitoring systems employing Deep Learning-based data processing.

Li-ion cell designs, component integrity and manufacturing processes all have critical influence on the safety of Li-ion batteries. Any internal defective features that induce a short circuit, can trigger a thermal runaway: a cascade of reactions, leading to a device fire. As consumer device manufacturers push aggressively for increased battery energy, instances of field failure are increasingly reported. Notably Samsung made a press release in 2017 following a total product recall of their Galaxy Note 7 mobile phone, confirming speculation that the events were attributable to the battery and its mode of manufacture. Recent incidences of battery swelling on the new iPhone 8 have been reported in the media, and the techniques and lessons reported herein may have future relevance. Here we look deeper into the key components of one of these cells and confirm evidence of cracking of electrode material in tightly folded areas, combined with a delamination of surface coating on the separator, which itself is an unusually thin monolayer. We report microstructural information about the electrodes, battery welding attributes and thermal mapping of the battery whilst operational. The findings point to the most likely combination of events and highlights the impact of design features, whilst providing structural considerations most likely to have led to the reported incidences relating to this phone.

Welding spot defect detection using deep learning methods provides an effective way of body-in-white quality monitoring. Based on the existing Faster R-CNN model, this paper proposed an improved faster R-CNN model for resistance welding spot surface defect inspection to improve inspection efficiency and accuracy. The model contains the following improvements. Firstly, the improved algorithm uses anchor box with higher confidence output by the RPN network to locate welding spots. When a defect is detected and the detection system is in a suspended state, the Fast R-CNN network is used to confirm the defect category and details. Secondly, a new pruning model is proposed to replace the entire backbone neural network, which unnecessary convolutional layers and connection layers are deleted, and some parameters of each hidden layer are further reduced. On the premise of ensuring detection accuracy, the parameter quantity is extremely reduced, and the speed is improved. Experiments show that the model proposed in this paper took about 15ms for one single image test, and both the detection accuracy and recall rate reached over 90% according to the test on our dataset. This deep learning model meets the requirements of welding spot defect detection.

Friction stir welding (FSW) is a solid state welding process for joining metallic alloys and dissimilar metals. It has emerged as an alternative technology for welding high strength alloys that are difficult to join with conventional techniques. FSW is used to produce products with better mechanical properties. Now a days aluminum alloys have been widely used in several industrial applications such as aerospace, marine, automobile and commercial applications due to their light weight structure, better mechanical properties and high corrosion resistance.In this work, three welding parameters such as spindle speed, welding speed and plunge depth were considered for friction stir welding. FSW was carried out between dissimilar aluminum alloy plates (AA6061 and AA 8011) to produce butt joint.A Box-Behnken design with three factors and three levels was chosen to minimize the number of experimental conditions .The tensile strength and hardness of the welded regions were evaluated. The optimum level settings and the major parameters that influence the joint strength were obtained by Box-Behnken design.

To weaken the harm of Al-Si coating and increase the strength of welded joint, variable thickness of Ni foil (Ni, an austenitic formation element) was added into the lap laser welding Al-Si coated 22MnB5 hot stamping steel/galvanized steel joints. The joints' weld appearance, microstructure, and mechanical properties were explored. The weld altered from X-shape to Y-shape with the increased thickness of Ni foil. During welding, Al-Si coating was melted and diluted into the welding pool, forming δ-ferrite (a rich-Al phase with low toughness and strength) in FZ and FB. This phase deteriorated the strength of the joints. After adding Ni, the amount and size of the δ-ferrite phase decreased. With a significant thickness of Ni foil, δ-ferrite would disappear. However, a new phase (FM, rich-Ni phase) probably formed except PM(a no or negligible Ni phase). The heat-affected zone (HAZ) on the side of 22MnB5 comprised a coarse martensite zone, refined martensite zone, martensite+ferrite zone, and tempered martensite zone from the FZ to the basic material. HAZ on the side of galvanized steel mainly contained ferrite and pearlite. After adding Ni foil, the strength of the joint was more than that without Ni. The maximum strength of the joint can be up to 679MPa because of the disappearance of δ-ferrite. Meanwhile, the toughness of the joint increased. The fracture mode was from three mixed fractures(cleavage, quasi-cleavage, and dimple) to one fracture(dimple).

The purpose of this study is to propose a consecutive manufacturing process system to secure the productivity of excellent STKN540B steel tube in the respect of economy and safety as the supporting material for mega structures such as building, bridge and ship. The components of consecutive manufacturing are press-bending, orbital auto welding and steel tube correction. By using STKN540B a high-strength steel material with low yield point that requires a special manufacturing process unlike other steel materials, an actual tube manufacturing is carried out at each stage in this experimental study. With this, the quality of steel tube and the efficiency of the manufacturing process are analyzed to draw out some points to improve in the future.

Dissimilar welds between ferritic and austenitic steels represent a good solution for exploiting the best performance of stainless steels at high and low temperatures and in aggressive environments, while minimizing costs. Therefore, they are widely used in nuclear and petrochemical plants, however, due to the different properties of the steels involved, the welding process can be challenging. Fusion welding can be specifically addressed to connect low-carbon, or low-alloy steels, with high-alloy steels, which have similar melting point. Welding of thick plates can be performed with electric arc in multiple passes or in a single pass by means of a laser beam equipment. Since microstructure and consequently mechanical properties of the weld are closely related to composition, the choice of the filler metal and processing parameters, which in turn affects the dilution rate, plays a fundamental role. Numerous technical solutions were proposed for welding dissimilar steels and much research was developed on the weldment metallurgy; therefore, this article is aimed at a review of the most recent scientific literature on the issues relating to the fusion welding of ferritic / austenitic steels. Two specific sections are dedicated respectively to electric arc and laser beam welding; finally, metallurgical issues, related to dilution and thermal field are debated in the discussion section.

Knowledge of the temperature evolution is crucial to understand and control laser beam welding of low-melting materials. Existing temperature determination approaches are restricted to i) one-dimensional temperature information (e.g. ratio-pyrometers), ii) a priori knowledge of the emissivity (e.g. thermography) and iii) high temperature regions (e.g. two-wavelength imaging). In this paper, a ratio-based two-color-thermography approach is developed that allows for two-dimensional temperature determination in low-melting temperature ranges (< 1200 K). For static measurement situations it is demonstrated, that temperature can be determined despite variation in signal intensity and emissivity with high accuracy. The two-color-thermography set-up is further transferred into a commercial laser beam welding machine and experiments are conducted for varying process parameters. The direct application of the developed two-color-thermography system in dynamic process situations is limited as image artifacts presumably caused by internal reflections inside the optical beam path are present.

This work studied the corrosion of welded pipes and how welding destroyed surface film of pipes. Surface reaction of a welded pipe is key to understanding phenomena and important factors during the corrosion. This paper presents experiment and CFD modeling approaches of a welded pipe corrosion under salt vapor condition. The pipes were welded at currents of 60 A,70 A and 80 A to observe the effect of welding current on corrosion. A welded pipe is a stainless-steel ASTM A312 grade 304L and period of experiment about 0-600 hours that they are tested in vertical and horizontal alignments. In CFD software, there is not direct model of corrosion but it can use surface reaction and create add-on species and chemical reaction technique for imitating the corrosion mechanism. The modeling approaches of corrosion have presented in 3-dimensional transient times in CFD simulation. Surface reactions were performed by Species Model which involve site species. Site species in Species Model took place at gas-solid interfaces and in this case are salt vapor and surface pipe. Chemical reaction rate on the surface controls lost weight of a welded pipe and the model can be validated with experiment. In conclusion, in period 0-600 hours error between CFD modeling and experiment have error trend decreased. The error at 600 hours is 6% both of vertical pipe and horizontal pipe test. The modeling approaches closely with the performed experiment and can be accepted. Moreover, the model is able to predict corrosion of a welded pipe of different sizes and their lost weight after 600 hours without experiment. Also the model can predict lifetime of pipe.

Aluminium matrix composite’s overall quality is impacted by the friction stir process parameters, which have a major impact on the microstructure, soundness, and particle dispersion inside the stir zone. Although it requires a lot of experimentation, optimizing these factors is vital. For the purpose of optimizing the ultimate tensile strength and microhardness of the AA5083/Silicon carbide and AA5083/Coal composites fabricated by FSP, this work used the Taguchi L9 design of experiments. Three process parameters were investigated at three levels each. For the AA5083/Silicon carbide composite, the results of the ANOVA analysis showed rotational speed has a larger impact on ultimate tensile strength while forAA5083/coal tilt angle has a larger impact on ultimate tensile strength. On the other hand, rotating speed had a greater effect on microhardness and percentage elongation of the AA5083/Coal and AA5083/Silicon carbide composite joints, according to ANOVA analysis. The need for specific process optimization for each composite was highlighted by the fact that different combinations of parameters were best for obtaining the necessary attributes in the AA5083/Silicon carbide and AA5083/Coal composites.

This paper proposes a methodology for multi-criteria calibration of a thermo-mechanical model for numerical simulation of welding in vacuum. A finite element model of a steel plate is created. Experimental and computational data are obtained. An inverse problem is formulated for the vector identification of five calibration parameters from the heat flow model. They are evaluated for adequacy with controlled accuracy according to four criteria. An optimization problem is solved using a two-step interactive procedure. The parameter space studying method (PSI) has been applied to the study of multidimensional regions by means of quasi-uniform sounding. A Pareto-optimal set is defined. It is used to determine reduced ranked Pareto subsets by -selection. Salukvadze optimum is also determined.

With increasing power and speed of laser welding, in-process monitoring has become even more crucial to ensure process stability and weld quality. Due to its low cost and installation flexibility, acoustic process monitoring is a promising method and has demonstrated its effectiveness. Since its feasibility has been the focus of existing studies, the temporal resolution of acoustic emissions (AE) has not yet been addressed despite its utmost importance for realizing real-time systems. Aiming to provide a benchmark for further development, this study investigates the relationship between duration and informativeness of AE signals during high power (3.5kW) and high speed (12m/min) laser beam butt welding. Specifically, the informativeness of AE signals is evaluated based on the accuracy of detecting and quantifying joint gaps for various time windows of signals, yielding numerical comparison. The obtained results show that signals can be shortened up to a certain point without sacrificing their informativeness, encouraging to optimize the signal duration. Our results also suggest that large gaps (> 0.3mm) induce unique signal characteristics in AE, which are clearly identifiable from 1 ms signal segments, equivalent to 0.2mm weld seam.

A diffusion welding of coarse-grained and ultrafine-grained (UFG) specimens of titanium near-α alloy Ti-5Al-2V used in nuclear power engineering was made by Spark Plasma Sintering. The failure of the welded specimens in the conditions of hot salt corrosion and of electrochemical corrosion were shown to have preferentially intercrystalline character. In the case of presence of macrodefects, crevice corrosion of the welded joints was observed. The resistance of the alloys against the intercrystalline corrosion was found to be determined by the concentration of vanadium at the titanium grain boundaries, by the size and volume fraction of the β-phase particles and by the presence of micro- and macropores in the welded joints. The specimens of the welded joints of the UFG alloy have higher hardness, hot salt corrosion resistance and the electrochemical corrosion.

This study aimed to explore the feasibility of using airborne acoustic emission in laser beam butt welding for the development of an automated classification system based on neural networks. The focus was on monitoring the formation of joint gaps during the welding process. To simulate various sizes of butt joint gaps, controlled welding experiments were conducted, and the emitted acoustic signals were captured using audible to ultrasonic microphones. To implement an automated monitoring system, a method based on short-time Fourier transformation was developed to extract audio features, and a convolutional neural network architecture with data augmentation was utilized. The results demonstrated that this non-destructive and non-invasive approach was highly effective in detecting joint gap formations, achieving an accuracy of 98%. Furthermore, the system exhibited promising potential for low latency monitoring of the welding process. The classification accuracy for various gap sizes reached up to 90%, providing valuable insights for characterizing and categorizing joint gaps accurately. Additionally, increasing the quantity of training data with quality annotations could potentially improve the classifier model's performance further. This suggests that there is room for future enhancements in the study.

This study proposes a machine-learning-based framework for detecting mechanical damage in pipelines, utilizing physics-informed datasets collected from simulations for mechanical damage. The framework provides an effective workflow from dataset generation to damage detection and identification for three types of pipeline events: welds, clamps, and corrosion defects. While the study initially focused on optimizing the CNN structure using various advanced optimizers, it also investigated the impact of sensing systems on data classification and the effect of noise on classification performance. The study's analysis highlights the importance of selecting the appropriate sensing system for the specific application. The authors also found that the proposed framework is robust to experimentally relevant levels of noise, suggesting its applicability in real-world scenarios where noise is present. Overall, this study contributes to the development of a more reliable and effective method for detecting mechanical damage in pipelines. The proposed framework provides an effective workflow for damage detection and identification, and the findings on the impact of sensing systems and noise on classification performance add to its robustness and reliability.

Solid-phase joining is a technique used to fuse two materials by applying heat and pressure, causing plastic deformation without reaching the melting point. This method is applicable for similar and dissimilar materials, including metals, polymers, and ceramics, without the need for filler material. Among the various methods, Friction Stir Welding (FSW) is preferred for joining dissimilar materials due to its solid-state process, which enhances mechanical properties, metallurgical compatibility, and reduces distortion. FSW is particularly effective for materials with significant differences in melting points. The current project focuses on assessing the strength and mechanical properties of FSW joints between aluminum and polymer-based composites. FSW was selected for its ability to produce fine-grained, strong welds free from fusion-related defects such as porosity and cracks. Applications in sectors like automotive, aerospace, and shipbuilding are explored, with impact, hardness, and tensile tests conducted to evaluate joint performance. This comprehensive study includes literature review, fabrication, testing, and tool design to ensure a thorough understanding of dissimilar joint properties.