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Microstructure and Mechanical Property Improvement of Welded Metal Joints
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Microstructure and Mechanical Property Improvement of Welded Metal Joints

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

Deadline for manuscript submissions: closed (31 May 2024) | Viewed by 18961

Special Issue Editor

Dr. Jiankang Huang

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Lanzhou University of Technology, Lanzhou, China
Interests: welding of dissimilar materials; additive manufacturing welding physics and numerical simulation; laser processing of materials; welding process detection and control
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The welding of materials, especially metal materials, is a hot topic in research focused on material processes. With the continuous development of welding technology, methods for the welding of metal materials is becoming increasingly important. Therefore, research on technology and performance is essential. This Special Issue is focused on the latest developments in metal material welding; its goal is to cover the welding of metal materials and explore research on the microstructure, performance, and interface behavior of these materials. The topics of interest also include primary development trends, engineering applications, and the numerical simulation of metal material welding. This article will cover all these topics, including the same and different metal materials, metal matrix composites, and their applications. Regarding processes, it will cover various welding processes, including traditional methods and emerging techniques (laser, electron beam, etc.). We welcome the submission of articles covering truly novel elements in the world of metal materials and processes that can effectively solve the welding problem between metal materials.

Dr. Jiankang Huang
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • welding of dissimilar materials
  • welding methods
  • welding metal joints
  • residual stress
  • microstructural analysis
  • numerical simulation

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Published Papers (9 papers)

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Research

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18 pages, 15610 KiB  
Article
Improving Welding Penetration and Mechanical Properties via Activated-Flux Smearing by Tungsten Inert Gas Arc Welding
by Shiqi Yue, Yong Huang, Xiaoquan Yu, Jia Zhang, Yu Ni and Ding Fan
Metals 2023, 13(12), 2017; https://doi.org/10.3390/met13122017 - 15 Dec 2023
Cited by 2 | Viewed by 1499
Abstract
For the welding process of thick-walled structural components in liquid rocket engines, the activated-flux TIG method can effectively address issues such as the formation of intermetallic phases in the weld seams, thereby enhancing mechanical performance. The present study investigates the activated-flux TIG welding [...] Read more.
For the welding process of thick-walled structural components in liquid rocket engines, the activated-flux TIG method can effectively address issues such as the formation of intermetallic phases in the weld seams, thereby enhancing mechanical performance. The present study investigates the activated-flux TIG welding technique on 10mm thick 1Cr21Ni5Ti duplex stainless steel plates. Various activated-flux, including -SiO2, TiO2, V2O5, NiO, MnO2, CaO, AlCl3, CaF2, B2O3 Cr2O3, and Al2O3, were examined to understand their impact on the weld-bead geometry. The aim was to determine the optimal activator ratio for the effective welding of 1Cr21Ni5Ti duplex stainless steel. The weld-shift experiment confirmed that the deep penetration observed in flux-assisted welding is attributed to Marangoni convection in the molten pool. Comprehensive evaluations and analyses were performed on the microstructure and mechanical properties of the normal welded joint and the A-TIG welded joint. Finally, the study delves into a discussion on the factors influencing changes in the weld penetration, microstructure, and mechanical properties of the weld. Full article
(This article belongs to the Special Issue Microstructure and Mechanical Property Improvement of Welded Metal Joints)
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12 pages, 4220 KiB  
Article
Microstructures and Electrical Resistivity of Aluminum–Copper Joints
by Jinchang Guo, Chunkai Li, Jianxiao Bian, Jianrui Zhang and Baolong Geng
Metals 2023, 13(8), 1474; https://doi.org/10.3390/met13081474 - 16 Aug 2023
Viewed by 1448
Abstract
Using pulsed double electrode-gas metal arc welding, aluminum wires are joined to copper plates with fillers of different fractions of silicon. Two layers of different microstructures are formed near the Al-Cu interface: one consists of a hypoeutectic microstructure of α (Al) + Al [...] Read more.
Using pulsed double electrode-gas metal arc welding, aluminum wires are joined to copper plates with fillers of different fractions of silicon. Two layers of different microstructures are formed near the Al-Cu interface: one consists of a hypoeutectic microstructure of α (Al) + Al2Cu, and the other consists of an intermetallic compound (IMC) of Al2Cu. Increasing the heat input causes increases in the thicknesses of the IMC layer and the layer of the hypoeutectic microstructure. Si suppresses the growth of the IMC layer and assists the growth of the layer of the hypoeutectic microstructure. The effects of the interface microstructures and chemical compositions on the electric resistivity of the joints are analyzed. The electric resistivity of the joints increases with the increase in the thicknesses of the IMC layer and the layer of the hypoeutectic microstructure. The law of mixture is used to calculate the electric resistivity of the joints, which is in accordance with the experimental results. Full article
(This article belongs to the Special Issue Microstructure and Mechanical Property Improvement of Welded Metal Joints)
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14 pages, 5329 KiB  
Article
Welding of Ti6Al4V and Al6082-T6 Alloys by a Scanning Electron Beam
by Angel Anchev, Darina Kaisheva, Georgi Kotlarski, Vladimir Dunchev, Borislav Stoyanov, Maria Ormanova, Milka Atanasova, Vladimir Todorov, Petya Daskalova and Stefan Valkov
Metals 2023, 13(7), 1252; https://doi.org/10.3390/met13071252 - 9 Jul 2023
Cited by 4 | Viewed by 1300
Abstract
This work presents the results of an investigation into the influence of beam offset on the structure and mechanical properties of electron-beam-welded joints between Ti6Al4V and Al6082-T6 alloys. The experimental procedure involved the use of specific technological conditions: an accelerating voltage of 60 [...] Read more.
This work presents the results of an investigation into the influence of beam offset on the structure and mechanical properties of electron-beam-welded joints between Ti6Al4V and Al6082-T6 alloys. The experimental procedure involved the use of specific technological conditions: an accelerating voltage of 60 kV, an electron beam current of 35 mA, a specimen motion speed of 10 mm/s, and a beam offset of 0.5 mm towards both alloys, as well as welding without an offset. The phase composition of the joints was analyzed using X-ray diffraction (XRD). The microstructure and chemical composition of the seams were studied by scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX). The results obtained for the structure of the joints show that the beam offset has a significant influence on the structure. The microhardness was studied by means of the Vickers method. The results for the microstructure showed that the welding procedure without offset and with an offset towards the Ti alloy leads to inhomogeneous welded joints with a significant amount of intermetallics. The offset towards the Al alloy leads to the formation of a narrow area of TiAl3 phase. The measured microhardness corresponds to the increased amount of intermetallics in the case of offset towards the Ti alloy, with which the highest values were presented (about 58% higher than with Ti6Al4V plate). The results obtained for tensile properties show that the offset to the Al6082-T6 alloy leads to the highest values of tensile strength (TS) and yield strength (YS), which are twice higher than in welding without offsetting of the electron beam. Full article
(This article belongs to the Special Issue Microstructure and Mechanical Property Improvement of Welded Metal Joints)
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12 pages, 6608 KiB  
Article
The Effect of Cooling Temperature on Microstructure and Mechanical Properties of Al 6061-T6 Aluminum Alloy during Submerged Friction Stir Welding
by Kiran Wakchaure, Rakesh Chaudhari, Ajaykumar Thakur, Kishan Fuse, Luis Norberto Lopez de Lacalle and Jay Vora
Metals 2023, 13(7), 1159; https://doi.org/10.3390/met13071159 - 22 Jun 2023
Cited by 4 | Viewed by 1514
Abstract
Submerged friction stir welding (SFSW) is a new modification of friction stir welding. In this paper, 6 mm thick 6061Al-T6 alloy plates were welded using the friction stir technique under normal air and submerged water conditions at 108 mm/min welding speeds and a [...] Read more.
Submerged friction stir welding (SFSW) is a new modification of friction stir welding. In this paper, 6 mm thick 6061Al-T6 alloy plates were welded using the friction stir technique under normal air and submerged water conditions at 108 mm/min welding speeds and a rotational rate of 900 rpm. The cooling water temperature in SFSW varied at 0 °C, 35 °C, and 80 °C to clarify the effect of water temperature. The characteristic hourglass-shaped stir zone was observed in the macrostructure of all the samples. All the samples exhibited defect-free joints. The results revealed that the finer grain size of 2.43 μm was at 0 °C. The macrostructure of SFSW joints separated into the shoulder-driven zone and pin-driven zone due to the low-temperature difference between the environment and water media and the high heat absorption capacity of the water, which caused a more substantial cooling rate during water-submerged welded joints. The microhardness distribution of all the joints showed typical “W” shape characteristics. The microhardness for all submerged samples was higher than in normal air conditions due to the higher thermal cycling effect in submerged conditions. Improved dynamic recrystallization in the joint welded at 80 °C resulted in the highest tensile strength (~249 MPa) and microhardness (~95 HV). Full article
(This article belongs to the Special Issue Microstructure and Mechanical Property Improvement of Welded Metal Joints)
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12 pages, 6282 KiB  
Article
Electron-Beam Welding of Titanium and Ti6Al4V Alloy
by Georgi Kotlarski, Darina Kaisheva, Maria Ormanova, Borislav Stoyanov, Vladimir Dunchev, Angel Anchev and Stefan Valkov
Metals 2023, 13(6), 1065; https://doi.org/10.3390/met13061065 - 1 Jun 2023
Cited by 6 | Viewed by 2685
Abstract
This work presents the results of the electron-beam welding of commercially pure α-Ti (CP-Ti) and Ti6Al4V (Ti64) alloys. The structure and mechanical properties of the formed welded joints were examined as a function of the power of the electron beam. The beam power [...] Read more.
This work presents the results of the electron-beam welding of commercially pure α-Ti (CP-Ti) and Ti6Al4V (Ti64) alloys. The structure and mechanical properties of the formed welded joints were examined as a function of the power of the electron beam. The beam power was set to P1 = 2100 W, P2 = 1500 W, and P3 = 900 W, respectively. X-ray diffraction (XRD) experiments were performed in order to investigate the phase composition of the fabricated welded joints. The microstructure was examined by both optical microscopy, scanning electron microscopy (SEM), and energy dispersive X-ray spectroscopy (EDX). The mechanical properties of the formed joints were studied using tensile test experiments and microhardness experiments. The results of the experiments were discussed concerning the influence of the beam power on the microstructure and the mechanical properties of the weld joints. Furthermore, the practical applicability of the present method for the welding of α-Ti and Ti64 was also discussed. Full article
(This article belongs to the Special Issue Microstructure and Mechanical Property Improvement of Welded Metal Joints)
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20 pages, 48910 KiB  
Article
Investigation of the Mechanism of Powder Pool Coupled Activating TIG Welding
by Yong Huang, Boyang Wang, Jianhang Guo, Ding Fan and Shurong Yu
Metals 2023, 13(5), 830; https://doi.org/10.3390/met13050830 - 23 Apr 2023
Viewed by 1573
Abstract
As a highly effective welding method, PPCA-TIG (Powder Pool Coupled Activating Flux–Tungsten Inert Gas) welding aims to achieve automated activation of TIG welding through the use of suitable activating fluxes. However, due to the unique transitional behavior of activating elements, the mechanism of [...] Read more.
As a highly effective welding method, PPCA-TIG (Powder Pool Coupled Activating Flux–Tungsten Inert Gas) welding aims to achieve automated activation of TIG welding through the use of suitable activating fluxes. However, due to the unique transitional behavior of activating elements, the mechanism of PPCA-TIG is a little bit different from common activating TIG welding. In this research, a two-dimensional model is established to investigate the effect of four activating fluxes (TiO2, SiO2, MnO2, CaF2) on arc morphology and force. A series of welding experiments is performed to study the impact of the different activating elements on the molten pool. The results show that the increase in the penetration of TiO2 is related to the high arc temperature and great arc force and electromagnetic force in the molten pool. The problem of the softening of 3003 aluminum alloy welded joints is solved. Other activating fluxes are less effective than TiO2. The addition of calcium fluoride significantly affects penetration. The use of TiO2, SiO2 and MnO2 changes the molten pool viscosity and affects the molten pool oscillation, thus affecting the weld quality. Full article
(This article belongs to the Special Issue Microstructure and Mechanical Property Improvement of Welded Metal Joints)
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13 pages, 10695 KiB  
Article
Analysis of Droplet Transfer and Arc Swing in “TIG + AC” Twin-Wire Cross Arc Additive Manufacturing
by Xueping Song, Zhuoxuan Li, Jiankang Huang, Ding Fan and Shurong Yu
Metals 2023, 13(1), 63; https://doi.org/10.3390/met13010063 - 26 Dec 2022
Cited by 4 | Viewed by 2057
Abstract
Twin-wire and arc additive manufacturing (T-WAAM) has potential advantages in improving deposition efficiency and manufacturing functionally graded materials (FGMs), thus attracting much attention. However, there are few studies on the droplet transfer mode of T-WAAM. This paper analyzes the droplet transfer mode and [...] Read more.
Twin-wire and arc additive manufacturing (T-WAAM) has potential advantages in improving deposition efficiency and manufacturing functionally graded materials (FGMs), thus attracting much attention. However, there are few studies on the droplet transfer mode of T-WAAM. This paper analyzes the droplet transfer mode and arc swing in the “TIG + AC” twin-wire cross-arc additive manufacturing by in-situ observation with high-speed photography, revealing what factors influence the T-WAAM on deposition shaping the quality and what are the key mechanisms for process stability. Experiments show that with the main arc current provided by TIG 100 A and the twin-wire AC arc current 10 A, three different droplet transfer modes, namely the “free transfer + free transfer, bridge transfer + free transfer, bridge transfer + bridge transfer,” can be observed with the twin wires under different feeding speeds. The corresponding deposition and arc swing are quite different in quality. Through comparative analysis, it is found that the frequent extinguishment and ignition of the arc between electrode wires is the main factor for the instability in the additive manufacturing process. The “bridge transfer + free transfer” mode can obtain a large arc swing angle and a stable deposition, in which the cross arc has a significant stirring effect on the molten pool, and the deposition shape is well-made. Full article
(This article belongs to the Special Issue Microstructure and Mechanical Property Improvement of Welded Metal Joints)
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14 pages, 10976 KiB  
Article
Microstructure and Mechanical Properties of Arc Zone and Laser Zone of TC4 Titanium Alloy Laser–TIG Hybrid Welded Joint
by Hao Fan, Peng Zhou, Jie Li, Jiankang Huang, Yu Ni and Yuanyuan Hui
Metals 2022, 12(11), 1854; https://doi.org/10.3390/met12111854 - 30 Oct 2022
Cited by 5 | Viewed by 1863
Abstract
As a high-efficiency and high-quality welding technology, laser-tungsten inert gas (laser–TIG) hybrid welding has been widely used in the aerospace and marine equipment industries. Through laser–TIG hybrid welding of TC4 titanium alloy, the effect of the current on the weld formation, the microstructure [...] Read more.
As a high-efficiency and high-quality welding technology, laser-tungsten inert gas (laser–TIG) hybrid welding has been widely used in the aerospace and marine equipment industries. Through laser–TIG hybrid welding of TC4 titanium alloy, the effect of the current on the weld formation, the microstructure and mechanical properties of the arc zone, and the laser zone was studied. The results show that the molten pool in the arc zone will flow periodically, and the flow becomes more intense with an increase in the current, which will result in a finer grain size in the arc zone than in the laser zone, having the effect of eliminating pores. The spacing of the α′ martensite beams in the laser zone is narrower, with an average spacing of 0.41 μm. The β phase increases gradually with the increase in the current, which will lead to a downward trend in the average hardness of both zones. The average hardness value of the laser zone, containing more α′ martensite and less β phase, is slightly higher than that of the arc zone. The hardness uniformity of the laser zone is also significantly better than that of the arc zone. The tensile strength of the joint shows a trend of increasing first and then decreasing, and the joint with I = 50 A presented the highest tensile strength of 957.3 MPa, approaching 100% of the base metal, and fractured in the fusion zone. Full article
(This article belongs to the Special Issue Microstructure and Mechanical Property Improvement of Welded Metal Joints)
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Review

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22 pages, 11447 KiB  
Review
Ultrasonic Welding of Aluminum to Steel: A Review
by Changxin Zhang, Huan Li, Qianxi Liu, Chaowang Huang and Kang Zhou
Metals 2023, 13(1), 29; https://doi.org/10.3390/met13010029 - 22 Dec 2022
Cited by 13 | Viewed by 3837
Abstract
As a solid-state bonding technology, ultrasonic welding (USW) has the characteristics of green energy saving and environmental friendliness. It is more suitable for joining dissimilar metals than other welding technologies. The aluminum-to-steel USWed joint has been widely used in the automotive and aviation [...] Read more.
As a solid-state bonding technology, ultrasonic welding (USW) has the characteristics of green energy saving and environmental friendliness. It is more suitable for joining dissimilar metals than other welding technologies. The aluminum-to-steel USWed joint has been widely used in the automotive and aviation industries. Currently, there is no review literature report on aluminum-to-steel USW. The main physical phenomena of the USW process include interface temperature increase, ultrasonic softening, plastic deformation, formation and growth of the IMCs, and dynamic recrystallization. Hence, the microstructures and mechanical properties of aluminum-alloy-to-low-carbon-steel, aluminum-alloy-to-stainless steel, and aluminum-alloy-to-galvanized-steel-joints by USW are reviewed. Moreover, the effect of interface temperature, interface plastic deformation, and interface macrostructure and microstructure is explored. Lastly, tensile-shear and fatigue strength of joints and numerical simulation of the USW process are also discussed. In addition, some new application types of aluminum-to-steel USW are introduced. Finally, the future trends of aluminum-to-steel USW with guidance are provided. Full article
(This article belongs to the Special Issue Microstructure and Mechanical Property Improvement of Welded Metal Joints)
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