Article
Chemistry, Physical
Zhuoxin Li, Lingshan Ou, Yipeng Wang, Hong Li, Mariusz Bober, Jacek Senkara, Yu Zhang
Summary: Aluminum alloy 7075 was welded using a digital welding machine with different arc modes. The results showed that CMT-based welding had lower solidification cracking susceptibility, slower cooling rate, and reduced micro-segregation of alpha-Al dendrites compared to MIG welding. The T-(f(Al))(1/2) curve analysis demonstrated that CMT welding enhanced the bridging of adjacent dendrites, decreasing the tendency for solidification cracking.
Article
Automation & Control Systems
Qiang Wang, Bojin Qi, Yanling Xu, Aiping Wu, Yue Zhao, Huajun Zhang
Summary: To achieve stable arc length and droplet transfer, understanding the power-arc model and the relationship between various parameters in pulsed gas metal arc welding (P-GMAW) process is crucial. In this study, a linear model of the GMAW process was analyzed with reasonable assumptions, and a mathematical power-arc model of P-GMAW was established through experimental statistical methods using a commercial welding power supply. The mathematical model was then combined with an adaptive arc length control strategy in the P-GMAW process of Al-Mg alloy, using a self-developed welding power supply. Experimental results showed that the arc length remained uniform and achieved the desired droplet transfer mode without spatters and cracks, indicating the feasibility of the adaptive arc length control strategy in Al-Mg alloy welding.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Xuewei Fang, Guopeng Chen, Jiannan Yang, Yang Xie, Ke Huang, Bingheng Lu
Summary: The study investigates the fabrication of aluminum alloy samples using a newly designed Al-Zn-Mg alloy through different arc modes. Results show that the porosity of the samples varies with different arc modes, with the CMT + P mode producing samples with the lowest porosity of 0.97%. Mechanical properties of the fabricated samples are also dependent on the arc modes, with samples produced by the CMT + PA arc mode exhibiting the highest tensile and yield strength.
FRONTIERS IN MATERIALS
(2021)
Article
Materials Science, Multidisciplinary
Gaofeng Liu, Shihui Zhou, Pengyu Lin, Xuemei Zong, Zhikai Chen, Zhihui Zhang, Luquan Ren
Summary: In this study, wall-shaped NiTi components were fabricated using cold metal transfer (CMT) based wire arc additive manufacturing (WAAM) with optimized depositing speed. The microstructure, mechanical properties, and wear performance of the as-fabricated specimens were investigated, and the correlations between them were analyzed. The results showed that the depositing speed had a significant influence on the microstructure, mechanical properties, and wear resistance of the NiTi components. The optimized CMT process provided a promising approach for producing homogeneous and flexible NiTi structures.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Materials Science, Multidisciplinary
Bappa Das, Biranchi N. Panda, Uday S. Dixit
Summary: This study investigated the microstructural, mechanical, and tribological properties of ER70S-6 cladding layer on AA 6061-T6 substrate using CMT technology. Optimum process parameters were identified and observed for improved hardness, wear depth, coefficient of friction, and yield strength.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2022)
Article
Materials Science, Multidisciplinary
Tae Hyun Lee, Dong Hyuck Kam, Je Hoon Oh, Cheolhee Kim
Summary: This study utilized the cold-metal transfer process and electrode-negative polarity to stabilize the gas metal arc additive manufacturing (WAAM) process of titanium alloys. High-speed imaging was used to investigate the mechanisms of cathode plasma jets, arc plasma, and molten metal transfer. The study demonstrated that the instability of the gas metal arc WAAM process of titanium alloys can be overcome with the cold metal arc process in electrode-negative polarity.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Automation & Control Systems
Wenyong Zhao, Yanhong Wei, Xujing Zhang, Jicheng Chen, Wenmin Ou
Summary: In this investigation, an external longitudinal alternating magnetic field is introduced into the wire arc additive manufacturing system to optimize the fabrication quality of aluminum alloy. The study comprehensively examines the effects of the external magnetic field on the arc behavior, metal transfer, deposit morphology, microstructure, and mechanical properties of the WAAM process. The results show that the excitation current and frequency have significant influences on the process parameters and can improve the surface accuracy and microstructure uniformity of thin-wall parts.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Automation & Control Systems
Yazhou Zhang, Ming Gao, Yang Lu, Wenbo Du
Summary: In this paper, a cold metal transfer pulse advance (CMT-PA) arc mode was used for wire arc additive manufacturing of Al alloy. The effects of process parameters on surface morphologies and geometrical characteristics were investigated, and deposition width and height models were established. The study found that the spreading trends of droplets in horizontal and molten pool tangential directions determine the final deposition characteristics, and these trends are mainly influenced by heat input and arc force. The research provides an optimal process window for improved deposition forming, with high effective width percentage and low machining allowance, leading to enhanced material utilization and reduced manufacturing costs.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Divya Nalajala, Rama Kishore Mookara, Murugaiyan Amirthalingam
Summary: This study optimized the metal transfer characteristics in gas metal arc welding process to achieve low heat input and high productivity for welding aluminum sheets. Results showed that pulse short-circuiting technique has higher droplet transfer rate compared to conventional short-circuiting process.
METALLURGICAL AND MATERIALS TRANSACTIONS B-PROCESS METALLURGY AND MATERIALS PROCESSING SCIENCE
(2022)
Article
Engineering, Industrial
Peng Wang, Hanzheng Zhang, Hao Zhu, Qingzhuang Li, Mengnan Feng
Summary: Modified cold metal transfer heat sources were used in wire-arc additive manufacturing of AZ31 magnesium alloy for thin-wall components by adjusting processing parameters. The CMT characteristic produced wide and shallow weld beads with good wettability and low heat input. The resulting thin-wall components exhibited anisotropic mechanical properties with lower yield strength, higher elongation, and higher ultimate tensile strength in the deposition direction.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Materials Science, Characterization & Testing
Tushar Sonar, Mikhail Ivanov, Srinivasan Sambath, Chinnasamy Rajendran, Natarajan Ramachandran, Padmanaban Senthil Kumar, Muralimohan Cheepu, Jinyang Xu
Summary: The effect of GMAW and CMTAW processes on microstructure and mechanical properties of AA8011-H18 aluminum alloy joints was investigated. CMTAW joints showed improved tensile and yield strength compared to GMAW joints, while ductility decreased.
Article
Engineering, Manufacturing
Siyuan Han, Xinhua Tang, Guoqiang Liu, Lidong Xu, Haichao Cui, Chendong Shao
Summary: The tandem narrow-gap gas metal arc welding (NG-GMAW) is an advanced high efficient technology for joining thick section metals. However, the common defects such as lack-of-fusion (LOF) at groove sidewalls, porosity in weld bead are still hard to be avoided, especially for joining thick section of aluminum alloy. In this study, the LOF and its formation mechanism at varied arc length were investigated. It was found that the arc heat distribution influenced by the tandem arc arrangement is a critical factor to the formation of LOF. A properly adjusted arc length can improve the arc interaction and the weld formation.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Chemistry, Physical
Zhongrui Zhang, Junqi Shen, Ji Bi, Shengsun Hu, Yahui Zhen, Xianzheng Bu
Summary: By utilizing the cold metal transfer (CMT) technique and weaving wire and arc additive manufacturing (WAAM) method, a deposited wall of AZ91 magnesium alloy was successfully fabricated. The effects of the weaving arc on grain refinement and property enhancement of the AZ91 component were investigated and compared. It was found that introducing the weaving arc increased the effective rate of the deposited wall and reduced the temperature gradient of the molten pool. The weaving CMT-WAAM component showed improved mechanical properties and isotropy compared to the traditional cast AZ91 alloy.
Article
Materials Science, Multidisciplinary
Wenhao Zhang, Chenshi Ding, Haoran Wang, Wei Meng, Zhenlin Xu, Jiujun Wang
Summary: The study compared the effect of process parameters on the forming profile of nickel-based alloy deposited by plasma and cold metal transfer (CMT) wire-arc deposition. The ellipse function model showed higher similarity with the profile features of PAW and CMT deposition. In the experiments, incomplete fusion defect was observed at the weld toe with CMT deposition in SLMB, while both sides of the PAW deposition layer were smoother in SBML compared to CMT.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2021)
Article
Materials Science, Multidisciplinary
Chao Chen, Guorui Sun, Wenbo Du, Yue Li, Chenglei Fan, Huijing Zhang
Summary: This study achieved the same heat input by designing different combinations of welding parameters and analyzed the formation, microstructure, and mechanical properties of the weld bead. The results showed that under the same heat input, the welding current and voltage had a significant impact on the weld bead, affecting its penetration, width, spreadability, and hardness.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2022)
Article
Materials Science, Multidisciplinary
Qinghua Lu, Jiewen Jin, Peilei Zhang, Hua Yan, Haichuan Shi, Jian Zhao
Summary: The paper introduces an experimental study of micro-vibration-assisted laser welding on 6082 aluminum alloy, showing that the welded joints had fine and uniform crystal structures with good hardness and tensile strength performance. The findings provide reference for developing anti-fatigue designs and reliability evaluations.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2022)
Article
Materials Science, Multidisciplinary
Qi Jiang, Peilei Zhang, Zhishui Yu, Yingtao Tian, Songyun Ma
Summary: The 5% Fe-based amorphous reinforced AlCoCrFeNi high-entropy alloy specimens prepared by selective laser melting technique exhibited excellent performance in terms of grain size, microstructure, and internal stress. The addition of Fe-based amorphous phase led to the precipitation of FCC phase in the BCC matrix and improved the overall mechanical properties of the alloy.
Article
Optics
Hanxuan Huang, Peilei Zhang, Zhishui Yu, Lei Shen, Haichuan Shi, Yingtao Tian
Summary: This study investigated the formation of micro-nano textures on the surface of Zr55Cu16Ni15Ti10Al4 bulk amorphous alloy induced by femtosecond laser, comparing different structural characteristics and analyzing the effects of various process parameters. It was found that the self-organized microholes structure had the best effect in reducing bacterial adhesion on the material surface.
OPTICS AND LASER TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Xiaoqi Hou, Xin Ye, Xiaoyan Qian, Peilei Zhang, Qinghua Lu, Zhishui Yu, Chen Shen, Lin Wang, Xueming Hua
Summary: Ti-Al alloy was deposited by twin-wire plasma arc welding additive, and the effect of different preheating temperatures on the welding result was studied. The results showed that increasing the preheating temperature within a certain range can decrease transient stress and prevent cracks from occurring.
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2023)
Article
Materials Science, Multidisciplinary
Hua Yan, Guangyu Zhu, Haichuan Shi, Peilei Zhang, Haichao Li, Qinghua Lu, Zhiyuan Li
Summary: This study compared the microstructure and mechanical properties of K438 nickel-based high-temperature alloy samples prepared and heat-treated via selective laser melting (SLM). The findings suggest the significant impact of SLM process parameters and heat treatment on the material properties, highlighting the importance of these factors in material preparation.
MATERIALS CHARACTERIZATION
(2022)
Article
Nanoscience & Nanotechnology
Qinghua Lu, Yangling Ou, Peilei Zhang, Hua Yan
Summary: The SiC/AlSi10Mg composites were created using selective laser melting, and the impacts of process parameters on the density, microstructure, tensile characteristics, and fatigue properties of the composites were investigated. The results showed that the density of the composites was closely related to the laser energy density. The addition of SiC reinforcement significantly improved the fatigue resistance of the materials.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Optics
Hanxuan Huang, Peilei Zhang, Zhishui Yu, Xia Zhang, Lei Shen, Haichuan Shi, Hua Yan, Liqiang Wang, Yingtao Tian
Summary: This study utilized femtosecond laser technology to create micro-nano structures on the surface of Zr-based amorphous material, demonstrating that these structures have inhibitory effects on the adhesion of Escherichia coli and Staphylococcus aureus.
Article
Metallurgy & Metallurgical Engineering
Boyu Wang, Haichuan Shi, Zhishui Yu, Peilei Zhang, Qiran Cheng, Nan Song, Hua Yan
Summary: In this study, a Ti-Zr-Cu-Ni amorphous brazing filler was used to achieve vacuum brazing between TC4 titanium alloy manufactured by selective laser melting (SLM) and Inconel 718 superalloy. The influence of different brazing temperatures and times on the microstructure and mechanical properties of the joint were studied. The results showed that optimal mechanical properties were obtained when the brazing temperature was 930°C and the brazing time was 20 minutes.
WELDING IN THE WORLD
(2023)
Article
Engineering, Manufacturing
Junyi Feng, Daixiu Wei, Peilei Zhang, Zhishui Yu, Changxi Liu, Weijie Lu, Kuaishe Wang, Hua Yan, Laichang Zhang, Liqiang Wang
Summary: Biological high-entropy alloy (Bio-HEA) is a promising biomedical alloy with excellent mechanical properties and biocompatibility. Selective laser melting (SLM) technique is used to fabricate dense blocks with low Young's modulus and good compression property at room temperature. Triply periodic minimal surface (TPMS) lattice in the HEA structure, with Young's modulus close to that of human trabecular bone, allows for customization of shape and porosity, enabling Bio-HEA to meet various bone implant requirements.
JOURNAL OF MANUFACTURING PROCESSES
(2023)
Review
Materials Science, Multidisciplinary
Qingyong Liu, Di Wu, Qingzhao Wang, Peilei Zhang, Hua Yan, Tianzhu Sun, Jie Zeng, Mingliang Yan, Zhenyu Liu, Ruifeng Li
Summary: Laser-arc hybrid welding (LAHW) technology combines laser and arc heat sources to improve welding speed, penetration depth, and gap-bridging ability. This review focuses on the fundamental concepts and characteristics of droplet transfer behavior in LAHW, emphasizing the physical interaction between laser and arc and the effect of combined heat sources on the welding process. Critical factors affecting droplet transfer characteristics, such as laser-to-arc distance, heat source leading mode, shielding gas composition, and laser power, are identified. The review provides important insights into the understanding, progress, and future research directions of LAHW.
Review
Optics
Shijie Song, Qinghua Lu, Peilei Zhang, Hua Yan, Haichuan Shi, Zhishui Yu, Tianzhu Sun, Zhirong Luo, Yingtao Tian
Summary: This paper reviews the important theories of ultra-short pulse laser ablation, including electromagnetic theory and matter reorganization theory, and summarizes the complex physical processes and the most popular two-temperature model in ultra-short pulse laser ablation. It discusses the use of the two-temperature model to enhance single-pulse laser ablation analysis and promote the understanding of the micro-nano structures generated by ultra-short pulse laser ablation. Various complex two-temperature model methods for simulating the interaction between ultra-short pulse lasers and metals are introduced. The main difficulties faced by ultra-short pulse laser processing are listed and suggestions for future simulations of ultra-short pulse laser processing are put forward.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Chemistry, Physical
Zhongyi Luo, Di Wu, Peilei Zhang, Xin Ye, Haichuan Shi, Xiaoyu Cai, Yingtao Tian
Summary: The study investigates the feasibility of using acoustic emission measurement and deep learning for penetration monitoring in pulsed laser welding. Through laser welding experiments on aluminum alloys, the complete dynamics of the keyhole and the generation mechanism of acoustic waves were visualized and elucidated. An adaptive time-frequency technique called VMD was proposed to characterize the acoustic energy distribution among different frequency components under different welding penetrations. A novel hybrid model combining CNN and LSTM was designed to extract spatial and temporal acoustic features. Extensive experiments demonstrate high classification performance with a test accuracy of 99.8% and a standard deviation of 0.21, providing an alternative way to develop an efficient end-to-end penetration monitoring system for laser welding.
Article
Materials Science, Multidisciplinary
Pengcheng Jiang, Ruifeng Li, Yue Zhao, Xiaoqiang Zhang, Peilei Zhang
Summary: Nickel-based coatings were prepared by laser cladding assisted with rotating magnetic field, which reduced the defects, improved the microstructure, reduced residual stress, and enhanced the microhardness and wear resistance of the coatings. The wear mechanisms of the coatings were a mix of abrasive wear and adhesive wear, and with rotating magnetic field assistance, the wear resistance of the coating was greatly enhanced.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Optics
Yifan Li, Fei Wang, Hongbing Liu, Lei Yang, Peilei Zhang, Yuhua Wang, Huan Li
Summary: An experimental study found that surface roughness has a significant effect on the performance of laser-welded Invar 36 alloy joints. Four different surface roughness levels were achieved using pneumatic driven shot peening. The increase in surface roughness improves weld penetration but also results in coarse grains and joint softening. A surface roughness of 2.14 μm effectively eliminates weld porosity and achieves defect-free joints with the most ideal mechanical properties.
OPTICS AND LASER TECHNOLOGY
(2023)
Review
Materials Science, Multidisciplinary
Junbo Feng, Peilei Zhang, Hua Yan, Haichuan Shi, Qinghua Lu, Zhenyu Liu, Di Wu, Tianzhu Sun, Ruifeng Li, Qingzhao Wang
Summary: Electric vehicle battery systems are made up of various materials, and each system contains hundreds of batteries. Laser welding, with its advantages of non-contact, high energy density, accurate heat control, and easy automation, is considered the ideal choice for battery manufacturing. However, welding different materials together poses challenges and can affect the joint's microstructure, electrical and thermal properties.
