Review
Optics
Bo Ma, Xiangdong Gao, Yijie Huang, Perry P. Gao, Yanxi Zhang
Summary: Dissimilar metal composite structures are widely used to meet the requirements of lightness, corrosion resistance, electrical conductivity, and thermal conductivity. The use of dissimilar aluminium (Al) and copper (Cu) for lithium battery welding is increasingly discussed due to global energy conservation and emission reduction policies. Laser welding is a unique technology for Al and Cu, but it faces challenges such as poor laser absorption, unstable welding process, and formation of brittler intermetallic compounds (IMCs). This paper discusses the challenges and analyzes the effect of process parameters and laser output modes on the weld joint, as well as the research progress on filler metals and process monitoring.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Kethavath Kranthi Kumar, Adepu Kumar, Sarvana Sundar
Summary: This study investigates the microstructure characteristics, tensile properties, and work hardening behavior of friction stir welding (FSW) AA5083-AA6061 dissimilar aluminum alloys under different cooling conditions. The results show that water-cooled FSW joints exhibited higher ultimate tensile strength (UTS) and enhanced strain hardening coefficient and work hardening rate compared to air-cooled FSW joints. The microstructure evolution and texture components primarily evolved in FSW samples were also analyzed.
MATERIALS TODAY COMMUNICATIONS
(2023)
Article
Automation & Control Systems
Joon Ho Cha, Hae Woon Choi
Summary: Laser welding offers many advantages in the manufacturing of EV battery packs, with the ability to optimize results and tensile strength by adjusting output ratios and other conditions. Increasing power may widen weld seams and form small pores, but penetration depth does not significantly change.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Review
Materials Science, Multidisciplinary
Ivan Bunaziv, Odd M. Akselsen, Xiaobo Ren, Bard Nyhus, Magnus Eriksson
Summary: Aluminium alloys are widely used in various industries due to their high strength-to-weight ratios and resistance to corrosion, but their specific properties make welding challenging. Issues such as strength loss, porosity, and humping can occur during welding processes. Extensive research has been conducted on laser beam and laser-arc hybrid welding of aluminium alloys to address these challenges and improve the efficiency of the welding processes.
Article
Materials Science, Multidisciplinary
Cong Chen, Xuni Yin, Wei Liao, Yunzhong Xiang, Ming Gao, Yi Zhang
Summary: Increasing the laser scanning frequency and amplitude can improve the proportion of equiaxed grains and reduce the average diameter in the weld, leading to increased elongation. The scanning laser helps to enhance the strength of the weld fusion zone and provides a new way to improve the strength, safety, and service life of new energy power batteries through even distribution of elements and strengthening phases.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Materials Science, Multidisciplinary
Qipeng Dong, Xiaming Chen, Hiromi Nagaumi, Xiaonan Wang, Bo Zhang
Summary: Dissimilar-filler welding often leads to macrosegregation, which degrades the performance of weld joints. This study reveals a new mechanism for the introduction of macrosegregation during dissimilar-filler welding, involving liquid segregation induced by dynamic heterogeneous mixing between the filler and base metal melts in the weld pool. In the front portion of the weld pool, heterogeneous mixing occurs uninhibitedly due to convection and continuous heat source, while in other regions, the reduced temperature of the weld pool results in solidification dominating heterogeneous mixing. Insufficient or partial heterogeneous mixing freezes the liquid segregation into the weld metal, introducing macrosegregation.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Metallurgy & Metallurgical Engineering
Ma Yu-lin, Zhu Jian, Zhang Long-mei, Ren Zhi-qiang, Zhao Yang, Wang Wen-yu, Wang Xiao-ming, Hui Xi-dong, Wu Yong-ling, Zheng Hong-yu
Summary: This study establishes a numerical simulation model for hybrid laser-electric arc heat source welding of dissimilar Mg alloys and verifies its feasibility through experiments. The interaction mechanism between laser and electric arc in welding is investigated, and it is concluded that the hybrid heat source can improve welding parameters.
JOURNAL OF CENTRAL SOUTH UNIVERSITY
(2022)
Article
Metallurgy & Metallurgical Engineering
R. Pordzik, T. Mattulat, P. Woizeschke
Summary: The quality of the weld seam in deep penetration laser welding is strongly influenced by the process dynamics, particularly the fluctuations of the keyhole shape. Understanding the underlying physical processes and gaining control over keyhole stability are necessary to avoid defects. The keyhole wall temperature is a crucial factor in assessing metal evaporation rate and recoil pressure, but significant correlations with laser power and measuring depth were not identified.
WELDING IN THE WORLD
(2023)
Article
Automation & Control Systems
Herinandrianina Ramiarison, Noureddine Barka, Fatemeh Mirakhorli, Francois Nadeau, Christopher Pilcher
Summary: The wobbling technique enhances weld quality by oscillating the laser beam, widening the coverage area and improving mechanical properties. Optimization of laser power and amplitude can result in a predicted welded part with increased tensile strength and ductility.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Nana Kwabena Adomako, Giseung Shin, Nokeun Park, Kyoungtae Park, Jeoung Han Kim
Summary: High entropy alloys (HEAs) exhibit superior mechanical properties and have been used in structural materials in nuclear and aerospace applications. A dissimilar joint between CoCrFeMnNi-HEA and duplex stainless steel (DSS) was created through laser beam welding, resulting in a sound joint with FCC phase in the weld metal. Postweld heat treatment (PWHT) showed a decrease in hardness for the weld metal, HEA, and DSS, with HEA experiencing a more significant reduction. Additionally, a strength of 584 MPa with low ductility was achieved after welding, and applying PWHT resulted in increased ductility with only a marginal reduction in strength. Future studies will focus on using laser beam offset welding to improve the mechanical properties of dissimilar joints.
JOURNAL OF MATERIALS SCIENCE & TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Yong Wu, Gang Liu, Zhi-Qiang Liu, Ze-Jun Tang, Bin Wang
Summary: Dissimilar joining of Ti2AlNb and Ti60 rolled sheet was achieved through laser beam welding. The microstructures and mechanical properties of the joints were investigated, revealing the presence of various phases in the fusion zone and heat-affected zones. The tensile strength and elongation of the as-welded sheet were improved by heat treatment, particularly at 970 degrees C.
Article
Optics
Yunfei Meng, Jiangwang Fu, Mengcheng Gong, Shuai Zhang, Ming Gao, Hui Chen
Summary: By using a novel 8-shaped beam oscillation, the uneven heating and reaction at the interface in laser circular oscillating welding of Al/Mg lap-joint with Ti as interlayer were solved, leading to improved connection width and shear tensile force.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Taher A. Shehabeldeen, Yajun Yin, Xiaoyuan Ji, Xu Shen, Zhipeng Zhang, Jianxin Zhou
Summary: The tool rotational speed significantly influences the strength and hardness of the welded joint, with lower speed resulting in higher shear strength and hardness, as well as producing a hybrid fracture surface; while higher rotational speeds tend to lead to brittle fracture mechanisms.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Engineering, Mechanical
Anton Evdokimov, Nikolay Doynov, Ralf Ossenbrink, Aleksei Obrosov, Sabine Weiss, Vesselin Michailov
Summary: A numerical model was developed to compute distortions in laser-welded dissimilar overlap joints, considering properties of mixed steel-aluminum weld metal. Experimental results showed that the developed weld material model significantly improves the accuracy of thermomechanical simulations, with good agreement between computed and measured data.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2021)
Article
Automation & Control Systems
Zheng-tian Wang, Zhen-yu Xiong, Shu-yuan Jiang, Yi-ping Chen, De-an Hu, Dong-hai Cheng
Summary: Magnetic field-assisted welding plays a significant role in improving weld bead properties. This study conducted a full-factor experiment and built a numerical simulation model to investigate the mechanism of magnetic field influence on the dissimilar laser wire feed weld brazing profile of aluminium and copper. The results showed that increasing the magnetic flux density significantly improved the properties of the weld bead, including wetting angle, fluid flow direction, and intermetallic compounds. The computed and measured distortions also demonstrated good agreement in the fusion zone.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Nanoscience & Nanotechnology
Giulio Marchese, Simone Parizia, Masoud Rashidi, Abdollah Saboori, Diego Manfredi, Daniele Ugues, Mariangela Lombardi, Eduard Hryha, Sara Biamino
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2020)
Article
Nanoscience & Nanotechnology
Abdollah Saboori, Gabriele Piscopo, Manuel Lai, Alessandro Salmi, Sara Biamino
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2020)
Correction
Chemistry, Physical
Emilio Bassini, Giulio Cattano, Giulio Marchese, Sara Biamino, Daniele Ugues, Mariangela Lombardi, Gianfranco Vallillo, Benjamin Picque
Review
Chemistry, Multidisciplinary
Abdollah Saboori, Alberta Aversa, Giulio Marchese, Sara Biamino, Mariangela Lombardi, Paolo Fino
APPLIED SCIENCES-BASEL
(2020)
Article
Nanoscience & Nanotechnology
Abdollah Saboori, Ata Abdi, Seyed Ali Fatemi, Giulio Marchese, Sara Biamino, Hamed Mirzadeh
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2020)
Article
Nanoscience & Nanotechnology
Giulio Marchese, Emilio Bassini, Simone Parizia, Diego Manfredi, Daniele Ugues, Mariangela Lombardi, Paolo Fino, Sara Biamino
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2020)
Article
Materials Science, Multidisciplinary
Giulio Marchese, Simone Parizia, Abdollah Saboori, Diego Manfredi, Mariangela Lombardi, Paolo Fino, Daniele Ugues, Sara Biamino
Article
Materials Science, Multidisciplinary
Giulio Marchese, Margherita Beretta, Alberta Aversa, Sara Biamino
Summary: The study found that by adding a small amount of Ti6Al4V powder to Inconel 625, the alloy's hardness and tensile strength can be improved, mainly attributed to the elimination of segregations triggering solute strengthening. Through heat treatments, the alloy exhibits better mechanical properties, even stronger than the base alloy.
Article
Chemistry, Physical
Marina Cabrini, Sergio Lorenzi, Cristian Testa, Francesco Carugo, Tommaso Pastore, Diego Manfredi, Sara Biamino, Giulio Marchese, Simone Parizia, Fabio Scenini
Summary: The research focused on the stress corrosion cracking (SCC) and hydrogen embrittlement resistance behavior of Alloy 625 fabricated by LPBF. The alloy was found to be immune to SCC, but there was a possibility of hydrogen embrittlement under specific conditions.
Article
Chemistry, Physical
Alessandra Martucci, Alberta Aversa, Diego Manfredi, Federica Bondioli, Sara Biamino, Daniele Ugues, Mariangela Lombardi, Paolo Fino
Summary: The primary goal of this study was to optimize the Scalmalloy (R) LPBF process parameters by setting power values suitable for lab-scale machines. The research found that the microstructural and mechanical behavior of the alloy remained stable at volumetric energy densities higher than 175 Jmm(-3). Low-energy heat-treated samples produced with lab-scale machines showed outstanding mechanical performance compared to energy-intensive industrial production.
Article
Chemistry, Physical
Alessandro Carrozza, Giulio Marchese, Abdollah Saboori, Emilio Bassini, Alberta Aversa, Federica Bondioli, Daniele Ugues, Sara Biamino, Paolo Fino
Summary: This study focuses on the effect of different heat treatments on the Ti-6Al-4V alloy processed by electron beam melting (EBM). The results show that super beta-transus annealing reduces anisotropy generated by the EBM process and the aging treatment further improves the microstructure and mechanical properties of the alloy.
Article
Materials Science, Multidisciplinary
Fabrizio Marinucci, Giulio Marchese, Emilio Bassini, Alberta Aversa, Paolo Fino, Daniele Ugues, Sara Biamino
Summary: Inconel 625 (IN625) is easily processed through laser powder bed fusion (LPBF) due to its high weldability. This alloy, commonly used in industrial applications, undergoes specific heat treatments to tailor microstructure features and mechanical performance. However, thermal exposure causes a phase transformation leading to reduced ductility and toughness, highlighting the importance of studying material behavior at service temperatures.
Article
Materials Science, Multidisciplinary
Pietro Antonio Martelli, Antonio Sivo, Flaviana Calignano, Emilio Bassini, Sara Biamino, Daniele Ugues
Summary: This study aims to investigate the processability of Rene 80 using laser powder-bed fusion (L-PBF). By optimizing the laser power, scan speed, and hatching distance, the crack density and pore area fraction of the alloy were minimized. Five sets of parameters were selected that resulted in a crack density lower than 100 μm/mm² and a pore fraction between 0.045% and 0.085%. The intra-print and inter-print repeatability of the optimal parameter sets were studied, showing consistent porosity values and low variation in crack density. Microstructural features of the alloy were also investigated after achieving optimal densification.
Article
Chemistry, Physical
Hanieh Bakhshi Farkoush, Giulio Marchese, Emilio Bassini, Alberta Aversa, Sara Biamino
Summary: The microstructures of intermetallic gamma-titanium aluminide alloys processed by EB-PBF are affected by Al evaporation, which is mainly determined by the process parameters. The current work aims to reduce Al-loss and microstructure inhomogeneity by using low energetic parameters and high beam speed in the pre-heating and melting steps during EB-PBF. The results showed that the HIP treatment effectively densified the capsules and reduced the area shrinkage, and applying low energetic parameters during melting decreased the formation of previous particle boundaries and resulted in smaller alpha(2) concentration and size.
Article
Engineering, Mechanical
F. Sausto, G. Marchese, E. Bassini, M. Calandri, S. Biamino, D. Ugues, S. Foletti, S. Beretta
Summary: Additive manufacturing shows promise for producing components for internal combustion engines, but issues such as poor surface quality, internal defects, and anisotropic mechanical behavior can impact fatigue strength. The study investigates the influence of building direction on component performance and crack propagation mechanisms.
FATIGUE & FRACTURE OF ENGINEERING MATERIALS & STRUCTURES
(2021)
