Article
Materials Science, Multidisciplinary
Mingfeng Li, Shanglu Yang, Yanjun Wang, Wu Tao
Summary: Reliably welding aluminum to steel is crucial in the automotive industry to achieve lightweight body structures. The proposed resistance spot welding process successfully joins AA6016 aluminum alloy and press hardened steel, forming an effective joint between the two materials.
Article
Engineering, Manufacturing
Hong Li, Weijia Yan, Zhuoxin Li, Bober Mariusz, Jacek Senkara, Yu Zhang
Summary: A CALPHAD-coupled finite element model was established to investigate the formation mechanism of hot cracks in dissimilar resistance spot welding joints. The results showed that the composition of the local area played a key role in crack initiation. Two types of liquation cracks, Type I and Type II, were observed at the interface of the nugget and the base materials. Metallographic and energy dispersive spectrometer analysis revealed that the Type I cracks were filled by liquid within the nugget, while the Type II cracks and solidification cracks created no-bonding areas. The Type II cracks deteriorated the mechanical properties of the joints.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Materials Science, Multidisciplinary
Hongyang Cao, Hongliang Li, Dan Wang, Hongbo Xia, Ke Han, Zeyu Wang, Qiang Zhu, Duo Liu
Summary: This investigation examined the feasibility of laser welding of TC4 titanium alloy and SiCp/6092Al matrix composites with different lap structures. The results showed that the welding formation, microstructure, mechanical properties, and intermetallic compounds varied between the two different laser lap joints. The TC4/AMC lap joints exhibited less porosity and cracks and achieved a higher tensile shear strength compared to the AMC/TC4 joint.
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)
Article
Materials Science, Multidisciplinary
Hideki Yamagishi
Summary: By using the spot forge-welding method, successful dissimilar lap joining of SUS304 and A5083 was achieved with a tensile shear load of 4.5kN, short bonding time, and a thin reaction layer at the bonded interface, establishing a high-strength process with virtually no intermetallic compounds.
MATERIALS TRANSACTIONS
(2021)
Article
Materials Science, Multidisciplinary
Jiang Yu, Hongtao Zhang, Bo Wang, Chong Gao, Zhichao Sun, Peng He
Summary: Dissimilar metal joining between Q235 mild steel and TC4 titanium alloy was successfully achieved using resistance welding with interlayer, which resulted in welded joints with higher strength compared to conventional resistance spot welding. No apparent welding defects were observed in the welded joints.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Review
Engineering, Industrial
Jin Yang, J. P. Oliveira, Yulong Li, Caiwang Tan, Chenkai Gao, Yixuan Zhao, Zhishui Yu
Summary: The use of multi-material structures is an effective solution to reduce weight and emissions in the automotive industry. However, joining aluminum alloys to steels is challenging due to their mismatched properties. Laser-based processes have been explored to overcome this issue and this review examines the recent achievements and progress in this field, evaluating factors such as joining conditions, filler materials, microstructure, and mechanical properties.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Qiaoling Chu, Tuo Xia, Lin Zhang, Pengkang Zhao, Min Zhang, Jianming Zheng, Fuxue Yan, Peng Cheng, Cheng Yan
Summary: In this research, Cu-base fillers with different V ratios were designed for the butt joining of explosion-welded titanium/steel bimetallic plate. It was found that the V content significantly influenced the formation of compounds at the weld interfaces, which in turn affected the mechanical properties of the weld metals. Strategies for improving the overall mechanical properties in the future were suggested.
Article
Materials Science, Multidisciplinary
Kambiz Moradi, Seyyed Ehsan Mirsalehi
Summary: In this study, lap joints between AA6061-T6 aluminum alloy sheets and St14 low-carbon steel sheets were achieved using the friction stir spot welding-brazing method with a pinless tool and a zinc interlayer. The effects of rotating speed and dwell time on the microstructure and mechanical properties were investigated. The joints exhibited sound shapes and the maximum tensile-shear failure load (TSFL) was observed to be over 4.2 kN for all the joints.
METALS AND MATERIALS INTERNATIONAL
(2023)
Article
Nanoscience & Nanotechnology
Xiaopei Wang, Yoshiaki Morisada, Hidetoshi Fujii
Summary: A high-strength Fe/Al dissimilar joint was successfully fabricated using double-sided friction stir spot welding with adjustable probes, which introduced strong mechanical interlocks at the interface and a uniform IMC layer. The 30 nm IMC layer composed of a ternary phase of Al?Fe?Si, induced by fresh surface from the adjustable probes, resulted in a high-strength welded joint. This novel technique was effective and productive for joining dissimilar materials.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Materials Science, Multidisciplinary
Huan He, Zhaoxian Liu, Lixin Zhang, Wenzhen Zhao, Ao Fu, Xiaoyang Yi
Summary: The joining of aluminum alloy and Ti-Ni-Hf shape memory dissimilar metals was achieved by cold metal transfer (CMT) welding-brazing with an Al-based filler. The relationship between heat input, microstructures, and joint strength was investigated. The joint consisted of three regions: the Al/SMA brazing interface, weld metal zone, and Al-weld metal zone. The interfacial intermetallic compound (IMC) with a strip or needle-like morphology was identified as TiAl3. The IMC exhibited an inhomogeneous morphology along the brazing interface. The Ti-Ni-Hf SMA adjacent to the interface retained reversible martensitic transformation and its phase transition temperature slightly increased with distance from the interface. Increasing heat input led to an increase in IMC thickness and a decrease in joint strength. The maximum tensile strength achieved was 122 MPa at a heat input of 553.6 J/mm. Fracture initiation occurred at the interface between the IMC and Ti-Ni-Hf and propagated along the interface.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Industrial
Peizhi Xu, Xueming Hua, Chen Shen, Ye Huang, Fang Li, Yuelong Zhang
Summary: Further development of car lightweighting relies on the reliability of Al/steel dissimilar joints, and a numerical model has been developed to calculate the thickness of the Fe2Al5 intermetallic compound (IMC) layer.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Qing Jiang, Jin Yang, Rui Xiao, Min Zheng, Jiawei Jiang, Jing Xue, Wenhu Xu, Jiayi Xu, Hua Zhang
Summary: In this study, laser spot welding technology was used for the first time to join low carbon steel and AA5052 aluminum alloy using a FeCoNiCrMn equimolar high entropy alloys (HEAs) interlayer. The addition of the HEA interlayer promoted the formation of a Fe-rich Fe-Al IMC with reduced brittleness and hardness. As a result, the joint fracture load increased from 963 N to 1473 N and the displacement dramatically increased from 0.66 mm to 3.32 mm. Another contributing factor to the outstanding ductility of the dissimilar laser joint was the formation of a conical fusion zone, which enabled both metallurgical bonding and mechanical interlocking at the interface.
Article
Materials Science, Multidisciplinary
Mohammad Zare, Majid Pouranvari
Summary: Metallurgical bonding between Al and Cu was achieved through the brazing mechanism, leading to the formation of a complex microstructure in the joint. The peak load and energy absorption of the Al/Cu joints were found to be controlled by the effective length of the solid/liquid reaction zone and the thickness of the theta-Al2Cu primary solidification phase.
SCIENCE AND TECHNOLOGY OF WELDING AND JOINING
(2021)
Article
Materials Science, Multidisciplinary
Yu Zhang, Hong Li, Zhuoxin Li
Summary: In fusion welding, cast magnesium alloys are more prone to liquation cracking than wrought alloys. A fluid-mechanics-based analytical model was established to investigate the lack of cracking in cast magnesium alloys while cracking took place in wrought alloys. The model shows that liquid feeding is easier in the inter-grain zone of cast coarse-grained metal compared to wrought metal, leading to tight bonding of semi-solid grains in the cast magnesium alloy.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Automation & Control Systems
Kai Chen, Xun Liu, Jun Ni
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2017)
Article
Engineering, Manufacturing
Xun Liu, Gaoqiang Chen, Jun Ni, Zhili Feng
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2017)
Review
Materials Science, Multidisciplinary
Farhang Momeni, Seyed M. Mehdi N. Hassani, Xun Liu, Jun Ni
MATERIALS & DESIGN
(2017)
Article
Engineering, Manufacturing
Kai Chen, Xun Liu, Jun Ni
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2018)
Review
Automation & Control Systems
Kai Chen, Xun Liu, Jun Ni
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2019)
Article
Engineering, Industrial
U. H. Shah, X. Liu
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2019)
Article
Nanoscience & Nanotechnology
Jiarui Kang, Xun Liu, Mingjie Xu
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2020)
Article
Materials Science, Multidisciplinary
Umair Shah, Xun Liu
MATERIALS & DESIGN
(2020)
Article
Materials Science, Multidisciplinary
Xue Wang, Yanfei Gao, Xun Liu, Martin McDonnell, Zhili Feng
Summary: Friction stir welding is widely used in automotive and aerospace industries for its solid-state bonding and versatility. However, the lack of mechanistic understanding of tool-workpiece frictional behavior hinders the study of the relationship among processing parameters, material properties, and bonding extent.
Article
Automation & Control Systems
Chenyu Zhao, Xun Liu
Summary: A pressure-dependent velocity boundary condition based on wear theory is used for modeling self-reacting friction stir welding, providing a new perspective on understanding sliding/sticking transition. The importance of shear layer in weld formation is emphasized. The boundary condition can robustly capture the effects of welding speed on weld cross-section geometry.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Andrew Gilmore, Xun Liu
Summary: This study comprehensively analyzed the mechanical behavior and microstructural evolution of aluminum alloy AA2219-T87 under high deformation and strain rates at elevated temperatures using hot torsion tests. An integrated experimental and modeling approach was employed, with a finite element model developed to address local deformation and nonuniform temperature distribution. The calibrated material constitutive model, recrystallization model, and grain size model showed good matching with experimental data and can be used to model various manufacturing processes involving hot deformation of aluminum alloys.
ADVANCED ENGINEERING MATERIALS
(2022)
Article
Engineering, Mechanical
Jiarui Kang, Xun Liu, Stephen R. Niezgoda
Summary: This study proposes a novel approach to model the ultrasonic softening effect during metal plasticity and develops a directional softening model. Calibrated and validated with experimental data of pure copper, the model reveals that the stress reduction during ultrasonic softening is not homogeneous in the whole aggregate but depends on grain orientation, with higher level of softening observed in plastically hard, high Taylor factor grains.
INTERNATIONAL JOURNAL OF PLASTICITY
(2022)
Article
Chemistry, Physical
Tianzhao Wang, Jiarui Kang, Mason Darnell, Xun Liu
Summary: This study thoroughly investigated a newly developed ultrasonically assisted hot-wire wire arc additive manufacturing process and drew important conclusions in the field of TiB2 nanoparticle reinforced AA7075 metal matrix nanocomposites.
JOURNAL OF ALLOYS AND COMPOUNDS
(2023)
Article
Materials Science, Multidisciplinary
Xun Liu, Mingjie Xu, Qianying Shi, Jiarui Kang, John Procario, Wenkao Hou, Murali Manohar
