Article
Automation & Control Systems
Andro Sidhom, Soheir Naga, Ahmed Kamal
Summary: This study investigates the possibility of friction stir spot welding of dissimilar polycarbonate to high-density polyethylene. The results show that an effective weld can be achieved at a moderate frictional heating temperature between the melting temperature T-m and glass transition temperature T-g of both materials.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Faliang He, Chuansong Wu, Lei Shi
Summary: This study developed a numerical simulation method to investigate the dynamic recrystallization behavior during friction stir welding of dissimilar Al/Mg alloys. The results show significant changes in grain size and dislocation density during the welding process, with the final grain size on the Al side being lower.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Review
Engineering, Manufacturing
Mayank Verma, Shuja Ahmed, Probir Saha
Summary: Dissimilar micro-friction stir welding is a preferred choice for joining dissimilar materials with thickness <= 1000 μm, especially in miniaturized components. However, challenges such as differences in mechanical and thermal properties of the materials, as well as issues related to reduced sheet thickness, hinder its full potential applications.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Materials Science, Multidisciplinary
Wenshen Tang, Xinqi Yang, Shengli Li, Huijun Li
Summary: This study investigated a zigzag line defect in the stir zone of friction stir butt-welded 12% Cr ferritic stainless steel joint, clarifying its characteristics and formation cause. The defect showed partly bonded feature with relatively higher hardness, and may affect impact toughness.
Article
Materials Science, Multidisciplinary
Hossein Khosrovaninezhad, Morteza Shamanian, Ahmad Rezaeian, Jalal Kangazian, Majid Nezakat, Jerzy A. Szpunar
Summary: The study demonstrated that selecting a weld pitch of 0.0625 mm/rotation resulted in defect-free welds with significantly improved hardness and shear strength in the weld zone. The grain refinement within the stir zones and reorganization of initial texture components of the base metals were key factors contributing to these enhancements.
MATERIALS CHARACTERIZATION
(2021)
Article
Nanoscience & Nanotechnology
Shengli Li, Xinqi Yang, Napat Vajragupta, Wenshen Tang, Alexander Hartmaier, Huijun Li
Summary: The research investigated the quantitative relationships between microstructural evolution and tensile properties in the stir zone of friction stir welded RAFM steel after post-weld tempering treatment. The results indicated that the high density of dislocation substructures is the crucial microstructure determining the yield strength of the stir zone for RAFM steel after PWTT.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Materials Science, Multidisciplinary
R. Aarthi, K. S. Vijay Sekar
Summary: Friction stir processing and the addition of Sc improved the mechanical and microstructural properties of TIG welded joints significantly, reducing grain size, increasing tensile strength, and improving hardness.
MATERIALS RESEARCH EXPRESS
(2022)
Article
Metallurgy & Metallurgical Engineering
J. X. Tang, L. Shi, C. S. Wu, M. X. Wu, S. Gao
Summary: In this study, double-side friction stir welding method was successfully employed for joining medium-thick Al/Cu dissimilar plates. It was found that the welding speed had a significant impact on the joint microstructure and mechanical properties, with low speed resulting in a nonuniform relatively thick intermetallic compound layer, high speed causing void defects, and medium speed yielding better joint properties.
ACTA METALLURGICA SINICA-ENGLISH LETTERS
(2022)
Article
Nanoscience & Nanotechnology
Madhav Raturi, Anirban Bhattacharya
Summary: This study investigates the influence of secondary heating on material behavior during friction stir welding through texture analysis, finding that secondary heating increases material flow volume but decreases hardness.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2021)
Article
Engineering, Industrial
J. Rinne, O. Seffer, S. Nothdurft, J. Hermsdorf, S. Kaierle, L. Overmeyer
Summary: The research shows a correlation between crack susceptibility in laser beam welding of stainless steel and copper with the copper content in the weld metal. By adjusting the weld metal composition to reduce the copper content or create copper dominated weld metals, the formation of cracks can be reduced. The cracks have no influence on the tensile shear strength, which is dependent on the connection width and mixing ratios.
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2021)
Article
Metallurgy & Metallurgical Engineering
A. Saravana Sundar, Adepu Kumar, Krishna Kishore Mugada
Summary: The study investigates the microstructural evolution and recrystallization mechanism of Ti-6Al-4V and Al6061 dissimilar friction stir welded joints. It is found that the Ti layers near the Al-Ti interface are initially stacked and later fragmented into fine particles under pressure. These particles are dispersed in the Al matrix by the stirring action of the tool, strengthening the stir zone. Recrystallization is observed in both base materials, with Al undergoing continuous dynamic recrystallization and Ti being influenced by adiabatic shear bands' formation.
TRANSACTIONS OF THE INDIAN INSTITUTE OF METALS
(2023)
Article
Engineering, Manufacturing
Shanqing Hu, Amberlee S. Haselhuhn, Yunwu Ma, Yongbing Li, Blair E. Carlson, Zhongqin Lin
Summary: This study utilized a traditional resistance spot weld process with Multi-Ring Domed welding electrodes to join AA5754-O to low carbon steel sheets in a coach peel configuration. The research revealed that asymmetric features resulting from relative rotation of the electrodes during deflection affected the resistance spot weld morphology, IMC characteristics, weld defect distribution, and hardness. The mechanism behind these weld asymmetries was further revealed through analysis of the variation in contact condition between electrodes and workpieces due to weld gun deflection.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Nanoscience & Nanotechnology
Nicolene van Rooyen, Madhumanti Bhattacharyya, Indrajit Charit, Michael R. Maughan
Summary: Simulated cracks in 304L stainless steel were repaired using low temperature friction stir welding. Indentation studies were conducted to understand the influence of microstructural features on mechanical properties across the weld and to measure the size of the weld zones quantitatively.
MATERIALS SCIENCE AND ENGINEERING A-STRUCTURAL MATERIALS PROPERTIES MICROSTRUCTURE AND PROCESSING
(2022)
Article
Automation & Control Systems
Yoshihiko Uematsu, Toshifumi Kakiuchi, Kenta Niimi, Paul Dario Toasa Caiza
Summary: A6061-T6 aluminum alloy plate was butt welded to type 304 stainless steel plate using friction stir welding, forming a dissimilar weld. Digital image correlation analysis was conducted on the top, bottom, and side surfaces of the weld to study the local deformation behavior near the joint interface under tensile loading. The results showed that the normal strain in the loading direction concentrated near the interface on both top and bottom surfaces, with different positions of strain-concentrated areas. The local stress-strain curves were obtained and the maximum strain and local 0.2% proof stress were determined.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
Article
Materials Science, Multidisciplinary
Akbar Heidarzadeh, Mousa Javidani, Mohammadreza Mofarrehi, Amir Farzaneh, X-Grant Chen
Summary: Underwater dissimilar friction stir welding of AA6061 and AA7075 aluminum alloys can improve the hardness performance of joints and exhibit different microstructural characteristics. Friction stir welding leads to a reduction in hardness values in all microstructural areas, but in underwater media, the hardness values in thermomechanically affected zones are higher compared to those reported in literature.
Article
Materials Science, Multidisciplinary
Suhong Zhang, Alan Frederick, Yiyu Wang, Mike Eller, Paul McGinn, Anming Hu, Zhili Feng
Article
Engineering, Industrial
Hui Huang, Jian Chen, Yong Chae Lim, Xiaohua Hu, Jiahao Cheng, Zhili Feng, Xin Sun
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2019)
Article
Automation & Control Systems
Yunhe Feng, Zongyao Chen, Dali Wang, Jian Chen, Zhili Feng
IEEE TRANSACTIONS ON INDUSTRIAL INFORMATICS
(2020)
Article
Materials Science, Multidisciplinary
Wei Zhang, Yanfei Gao, Zhili Feng, Xin Wang, Siyu Zhang, Lan Huang, Zaiwang Huang, Liang Jiang
Article
Materials Science, Multidisciplinary
Jian Chen, Yong Chae Lim, Donovan Leonard, Hui Huang, Zhili Feng, Xin Sun
Article
Chemistry, Physical
Yiyu Wang, Wei Zhang, Yong Chae Lim, Yanli Wang, Zhili Feng
Article
Chemistry, Physical
Koichi Taniguchi, Yong Chae Lim, Alexis Flores-Betancourt, Zhili Feng
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
Chemistry, Physical
Jiheon Jun, Yong Chae Lim, Yuan Li, Charles David Warren, Zhili Feng
Summary: The study shows that the use of polymer insulation can effectively mitigate galvanic corrosion at bolted joints between magnesium alloy and carbon fiber-reinforced composite, resulting in reduced corrosion depth and volume. In the polymer-insulated group, the reduction in joint strength post-corrosion was relatively small, while in the non-insulated group it was significantly greater.
Article
Engineering, Manufacturing
Wei Zhang, Dali Wang, Jian Chen, Hassan Ghassemi-Armaki, Blair Carlson, Zhili Feng
Summary: The root cause of post-weld baking on the mechanical performance of Al-steel dissimilar resistance spot welds has been identified using machine learning and finite element modeling. A deep neural network model correlated spot weld performance with joint attributes, stacking materials, and other conditions. It was found that post-weld baking reduces joint performance, with the extent of degradation depending on the stacking materials' thickness. Finite element modeling revealed that high thermal stresses during baking, caused by thermal expansion mismatch, lead to damage and cracking of the brittle intermetallic compound formed at the weld nugget interface during welding.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2023)
Article
Materials Science, Multidisciplinary
Zhili Feng, S. A. David, V. K. Manchiraju, D. A. Frederick, W. Thomas
Summary: Friction extrusion is a solid-state process that utilizes frictional heating and plastic deformation to synthesize and recycle metals and alloys into highly engineered materials. It is an energy-efficient, zero-emission, and economically competitive technology that eliminates the need for energy-intensive melting and solidification steps. This work introduces the concept and configuration of friction extrusion, analyzes its energy-saving advantage, demonstrates its feasibility with synthesizing Al alloys, and presents the results of metallographic and mechanical properties studies. The future prospects of friction extrusion technology are outlined.
Article
Chemistry, Analytical
Shenghan Guo, Dali Wang, Zhili Feng, Jian Chen, Weihong Guo
Summary: In this study, manufacturing domain knowledge was leveraged to enhance the accuracy and interpretability of convolutional neural networks (CNNs) in quality prediction. A novel CNN model called Di-CNN was developed, which learned from design-stage information and real-time sensor data and adaptively weighted these data sources during training. By using domain knowledge to guide model training, the proposed model achieved superior performance in quality prediction.
Article
Metallurgy & Metallurgical Engineering
Jiheon Jun, Vineet V. Joshi, Alasdair Crawford, Vilayanur Viswanathan, Donovan N. Leonard, Jian Chen, Piyush Updadhyay, Yong Chae Lim, Zhili Feng
Summary: Quantitative study was conducted on the galvanic corrosion of AZ31B joined with bare or Zn-coated DP590 steel by ultrasonic spot welding or linear friction stir welding. The corrosion volume and depth were analyzed based on cathode surface type and welding method. Experimental results showed that Zn-coated cathode surface significantly reduced Mg galvanic corrosion, while COMSOL modeling provided reasonable simulation but underestimated the corrosion volume.
JOURNAL OF MAGNESIUM AND ALLOYS
(2023)
Article
Engineering, Manufacturing
Hui Huang, Yiyu Wang, Jian Chen, Zhili Feng
Summary: Thermal distortion and residual stresses are important factors affecting the quality and reliability of steel parts manufactured by LPBF. A cost-effective model is needed to evaluate these heat effects to optimize the manufacturing process. The study compared the computational accuracy and efficiency of layer heating and track-layer scanning methods for simulating the thermo-mechanical response of IN625 tube parts built by LPBF. The layer heating method efficiently captured stress distribution patterns with reasonable accuracy, while the grouped track-layer scanning method predicted residual stresses and strains more accurately at a higher cost.
INTEGRATING MATERIALS AND MANUFACTURING INNOVATION
(2021)
Article
Robotics
Jinsong Chen, Jian Chen, Zhili Feng, Yuming Zhang
IEEE ROBOTICS AND AUTOMATION LETTERS
(2019)
