Article
Materials Science, Multidisciplinary
Hao Cheng, Liangang Zhou, Qijun Li, Dong Du, Baohua Chang
Summary: The process parameters have significant effects on spatter formation during laser welding, with low power and speed resulting in small and fast-moving spatter, while high power and speed leading to large and slow-moving spatter.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2021)
Article
Chemistry, Physical
Lei Kang, Xin Li, Jing Chen, Yu Zhang, Ting Wang
Summary: This research investigated the microstructures and mechanical properties of laser penetration welded joints of overlap steel-on-aluminum. It was found that adding a nickel interlayer significantly enhanced the tensile property of the joint and decreased the hardness of the intermetallic compounds, thus improving the toughness of the welded joint.
Article
Engineering, Aerospace
Jiafu Zhou, Dianwu Zhou, Huiming LI
Summary: Effective fusion welding joints between Ti and Al are difficult to obtain due to their thermal properties differences and the presence of brittle Ti-Al intermetallic compounds (IMCs). Laser fusion welding experiments were conducted on TC4 titanium and 7075 aluminum alloy, and the temperature field, ductility/brittleness, and chemical potential of elements were calculated. The addition of Nb foil was found to improve the mechanical properties of the weld, with the Ti-Nb-Al IMC layer forming at the interface and reducing brittleness. The joint properties of titanium/aluminum are enhanced with the addition of Nb foil.
CHINESE JOURNAL OF AERONAUTICS
(2023)
Article
Materials Science, Multidisciplinary
Won-Sang Shin, Dae-Won Cho, Donghyuck Jung, Heeshin Kang, Jeng O. Kim, Yoon-Jun Kim, Changkyoo Park
Summary: The pulsed laser welding of Al ribbon to Cu sheet for electrical interconnections in power electronic modules was studied, revealing the formation of intermetallic compounds and their impact on weld quality. Experimental conditions were optimized to minimize intermetallic compound formation, and computational fluid dynamics simulation helped understand the molten pool behavior during welding. Measurements of tensile shear strengths and electrical resistances showed a correlation with welding area, with mechanical strength decreasing and electrical resistance increasing with larger welding areas. Process window was developed to achieve defect-free Al/Cu joints with minimized intermetallic compound formation.
Article
Engineering, Industrial
Zhijie Zhang, Jian Huang, Jiaping Fu, Pulin Nie, Shiwei Zhang
Summary: This study proposed a new method of using a titanium mesh interlayer in laser welding-brazing aluminum and titanium to enhance the load capacity of Ti/Al joints. Experimental results revealed that the titanium mesh improved the spreading and wetting abilities of molten aluminum on the titanium surface, resulting in the formation of Al3Ti intermetallic compounds through the Ti/Al interface reaction. These improvements increased the microhardness and load capacity of the joints.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Engineering, Industrial
Lidong Xu, Xinhua Tang, Siyuan Han, Ruolin Zhang, Chendong Shao, Haichao Cui
Summary: The dynamic behavior of the molten pool in full penetration laser welding with or without backing gas for aluminum alloy was observed. It was found that the use of backing gas can greatly improve the formation of a root hump. A numerical model was developed to explain this phenomenon by considering the metallic vapor ejection process. The model showed that the flow pattern of the melt in the molten pool was deeply affected by the vapor ejection pattern, and the surface tension played an important role in improving the root hump formation.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Optics
Michael Wiegand, Alexander Kimm, Niklas Sommer, Linda Marks, Martin Kahlmeyer, Stefan Boehm
Summary: In this study, commercially pure titanium was welded to AISI 316L stainless steel using niobium as filler material. Pulsed Nd:YAG laser was used to achieve different mixing conditions for the materials. The results show that the weld seams, despite the use of filler material, have a high tendency to crack due to the formation of hard intermetallic compounds. However, by optimizing the process parameters, crack-free specimens can be obtained through uniform mixing of critical alloy elements. The use of multiple weld seams increases the maximum loads and lap-shear forces, exceeding the yield strength of the stainless steel. The biocompatibility of the niobium filler material makes this dissimilar material combination suitable for future medical technology applications.
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
Thermodynamics
Zixuan Wan, Hui-Ping Wang, Jingjing Li, Joshua Solomon, Yuanjing Zhu, Blair Carlson
Summary: This study investigated the remote laser stitch welding of thin-gage zinc-coated steel sheets in lap joint condition and proposed measures to predict spatter occurrence. A thermo-fluid numerical model was developed to study the physics of the welding process and calculate the parameters affecting spatter generation. The effects of welding parameters on spatter occurrence were numerically studied and found to be directly influenced by laser linear energy.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2021)
Article
Materials Science, Multidisciplinary
Xiao-Nan Wang, Li Xiong, Fe Teng, Ren-Dong Liu, Yu Du, Xin Xu, Ya-Jun Xing, Dong Lv, Xiang Li
Summary: This study investigates the influence of Al distribution in the fusion zone on the microstructures and properties of welded joints, and provides insights into the relationship between the distribution of Al and the microstructure and hardness of the weld. The findings also reveal the changes in Al distribution under different laser powers and its impact on the welded joints.
MATERIALS TODAY COMMUNICATIONS
(2023)
Review
Materials Science, Multidisciplinary
Daniel Wallerstein, Antti Salminen, Fernando Lusquinos, Rafael Comesana, Jesus del Val Garcia, Antonio Riveiro Rodriguez, Aida Badaoui, Juan Pou
Summary: This paper reviews recent research on laser joining of aluminum to steel, highlighting challenges and strategies in laser joining of dissimilar materials. It contributes to advancing the acceptance of laser joining in modern industries by discussing IMC formation and growth, as well as different strategies to minimize them.
Article
Optics
Yi Qi, Genyu Chen, Dezheng Liu
Summary: This study aims to prevent droplet spatter in laser welding of galvanized sheets. Through the analysis of a three-dimensional welding simulation model, the relationship between keyhole oscillation and flow behavior is revealed. It is found that the major reason for droplet spatter is the impact force of the reflux and eddy of the metal pool toward the keyhole. However, using a certain output proportion of coaxial annular and Gaussian laser source can significantly improve the problem.
OPTICS AND LASER TECHNOLOGY
(2022)
Article
Optics
Xuyang Chen, Gang Yu, Xiuli He, Shaoxia Li
Summary: A three-dimensional numerical model was established to analyze the influence of different leading configurations on hybrid laser-MIG welding of aluminum alloy, showing that the transport phenomena of the molten pool was strongly affected by the configuration. It was found that arc-leading configuration resulted in easier attainment of larger penetration depth, while laser-leading configuration led to a more homogeneous distribution of magnesium and zinc concentrations. The developed model can provide a theoretical basis for processing experiments.
OPTICS AND LASER TECHNOLOGY
(2021)
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
Chemistry, Physical
Sajid Ali, Joonghan Shin
Summary: With the increasing demand for electric vehicles, the challenges posed by the joining of dissimilar materials in the EV batteries need to be addressed. Laser beam welding shows promise for joining aluminum and copper, but the differences in thermal and metallurgical properties between the two materials make the production of Al-Cu joints challenging. Therefore, characterizing the weld and improving the welding process are vital for enhancing joint performance.
Article
Engineering, Manufacturing
Haodong Sun, Gaoyang Yu, Shuhai Chen, Jihua Huang, Jian Yang
Summary: High-frequency induction brazing of dissimilar Al/Steel metals using Zn-Al filler metals with different compositions was investigated. Zn-15Al filler metal showed the best wettability on aluminum, and a brazing gap of 0.3 mm resulted in the best filling performance. The use of Zn-2Al filler metal led to the most serious dissolution of aluminum in the brazing seam.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Materials Science, Ceramics
Yi Xiong, Zheng Ye, Jihua Huang, Jian Yang
Summary: SiCf/Ti3SiC2 composites were fabricated by hot isostatic pressing using Ti3SiC2 powder and SiCf as starting materials at 1200°C for 2 hours. The composites exhibited improved flexural strength and microhardness with increasing SiCf content, but also showed enhanced oxidation rate.
INTERNATIONAL JOURNAL OF APPLIED CERAMIC TECHNOLOGY
(2022)
Article
Engineering, Electrical & Electronic
Xianwen Peng, Yue Wang, Zheng Ye, Jihua Huang, Jian Yang, Shuhai Chen, Xingke Zhao
Summary: The high-tin-content Cu@Sn core/shell powder was successfully used for transient liquid-phase sintering bonding of high-temperature power device packaging. The resultant bonding layer could withstand temperatures up to 400 degrees C, and the shear strength of the joint was enhanced with the increase of bonding time and bonding temperature, reaching a highest value of 43.2 MPa. Additionally, a denser joint was achieved using the Cu@Sn core/shell powders compared to mixed powders.
JOURNAL OF ELECTRONIC MATERIALS
(2021)
Article
Materials Science, Multidisciplinary
Gaoyang Yu, Haodong Sun, Shuhai Chen, Tianpeng Zou, Jihua Huang, Jian Yang, Zhiyi Zhao
Summary: Five kinds of Zn-Al-Cu filler alloys were developed for high-frequency induction brazing of 6A02-T6 aluminum alloy in this study. Reliable joining of 6A02 aluminum alloy was achieved with novel Zn-Al-Cu filler metal under suitable processing parameters. The optimal composition of filler metal in this study is Zn-36Al-22.7Cu (wt.%).
JOURNAL OF MATERIALS ENGINEERING AND PERFORMANCE
(2022)
Article
Engineering, Industrial
Wanli Wang, Yonglei Wang, Jihua Huang, Zheng Ye, Jian Yang, Shuhai Chen, Xingke Zhao
Summary: The novel process utilizing reaction-composite brazing and transient liquid phase bonding successfully achieved low-temperature bonding and high-temperature resistance for joining C-SiC composite and GH4169 superalloy. The joints showed excellent comprehensive properties, with a high melting temperature of 1052 degrees C and maximum shear strengths of 234 MPa at room temperature and 101 MPa at 900 degrees C.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Engineering, Industrial
Zheng Ye, Jihua Huang, Zhi Cheng, Shifei Wang, Jian Yang, Shuhai Chen, Xingke Zhao
Summary: The newly developed HFAW-B welding process achieved a sound joint with a thin interfacial IMCs layer under a low heat input, while the traditional MIG process required higher heat input and resulted in thicker IMCs layer and cracking in the weld seam.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Engineering, Mechanical
Zitong Guo, Zhongde Shan, Jihua Huang, Debo Xue
Summary: This study investigated the Z-yarn frictional force distribution model and wear mechanism of Z-directional 3D preforms. A tensile force measuring device was designed to measure the frictional forces, and a neural network model was established to predict the friction at different positions of the preform. The study also examined the wear of Z-yarn at different frictional positions and after different times of implantation into the preform. The study's findings have important implications for improving the quality and efficiency of Z-directional 3D preform forming.
CHINESE JOURNAL OF MECHANICAL ENGINEERING
(2022)
Article
Materials Science, Multidisciplinary
Chao Lu, Yue Wang, Meng Yang, Yan Han, Jian Yang, Jihua Huang, Shuhai Chen, Zheng Ye, Yue Zhao
Summary: By using a porous NiFeWss interlayer prepared on the surface of a W substrate using electrolytic corrosion technology, diffusion bonding between 90WNiFe alloy and 30CrMnSiA steel was achieved, resulting in a joint with high tensile strength and elongation.
Article
Materials Science, Multidisciplinary
Yue Wang, Zheng Ye, Xianwen Peng, Jihua Huang, Jian Yang, Shuhai Chen, Xingke Zhao
Summary: In this study, the kinetics of Ni3Sn4 growth and the isothermal solidification kinetics in Ni-Sn transient liquid phase sintering bonding process were investigated. A kinetic model and parameter were established to describe the growth and isothermal solidification of Ni3Sn4. The experimental results confirmed the accuracy of the theoretical model and showed that the kinetics of TLPS bonding process can be accelerated by increasing the sintering temperature and decreasing the particle size.
METALLURGICAL AND MATERIALS TRANSACTIONS A-PHYSICAL METALLURGY AND MATERIALS SCIENCE
(2022)
Article
Optics
Gaoyang Yu, Shuhai Chen, Zhiyi Zhao, Zhongling Wen, Jihua Huang, Jian Yang, Shujun Chen
Summary: This study compared different filler wires for laser welding-brazing aluminum alloy to steel and found that Pure Al filler wire had the poorest fluidity, leading to decreased weld quality, while AlSi5 filler wire achieved the highest maximum tensile strength. The results provide guidance for filler wire selection in laser welding-brazing applications.
OPTICS AND LASER TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Xianwen Peng, Yue Wang, Zheng Ye, Jihua Huang, Jian Yang, Shuhai Chen, Xingke Zhao
Summary: This paper investigated the microstructure evolution and performance of high tin content Cu@Sn core/shell powder transient liquid phase sintering bonding. The formation and evolution mechanism of voids were analyzed. The results showed that the porosity in the joint decreased initially, then increased, and finally decreased again with bonding time. The joint exhibited excellent shear strength, electrical resistivity, and thermal conductivity.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Materials Science, Multidisciplinary
Pengfei Zhang, Decheng Wang, Peng Cheng, Chenxi Shao, Wei Zhu, JunYing Zhou, Jihua Huang
Summary: Electromagnetic induction heating was used for the heat treatment of 65Mn tape-steel, and the microstructure evolution and mechanical properties were investigated. The results showed that the treated material had lower microhardness and tensile strength, but higher elongation and corrosion resistance.
MATERIALS TODAY COMMUNICATIONS
(2022)
Article
Materials Science, Ceramics
Yi Xiong, Haodong Li, Jihua Huang, Zheng Ye, Jian Yang
Summary: TiC coated C-f/Ti3SiC2 composites were fabricated using SPS and HIP processes, exhibiting improved fracture toughness and Vickers hardness. The HIP process allows for better sintering and further enhances the mechanical properties of the composites. The control of reactive interface and the utilization of fiber pull-out and debonding mechanisms contribute to the improved properties.
JOURNAL OF THE EUROPEAN CERAMIC SOCIETY
(2022)
Article
Chemistry, Physical
Zhihang Zhang, Qiuguo Yang, Jihua Huang, Shuhai Chen, Zheng Ye, Jian Yang
Summary: The study investigated the Cu6Sn5/Cu interface with different structures using density functional theory and semi-classical Boltzmann transport theory, finding that the interface chemical bonds exhibit both ionic and covalent characteristics. Different interfacial structures showed varied bonding strength, electrical conductivity, and thermal conductivity.
SURFACES AND INTERFACES
(2022)
Article
Chemistry, Physical
Qiuguo Yang, Chao Lu, Yan Han, Xiaohua Chen, Jian Yang, Jihua Huang, Shuhai Chen, Zheng Ye
Summary: The influence of different Cu/W interfacial structures on resistance against harmful He atoms was investigated using density functional theory calculations. The Cu(111)/W(111) interfacial structure showed the greatest resistance to He weakening effect and He atom intrusion, making it the most promising Cu/W interfacial structure for improving service performance.
JOURNAL OF ALLOYS AND COMPOUNDS
(2022)
