Article
Materials Science, Multidisciplinary
Mengfei Cui, Zhentai Zheng, Peng Du, Liang Chang
Summary: In this study, AZ91/6061 dissimilar metal joints were successfully manufactured using double molten pool laser welding, and the process, microstructure, and mechanical properties of these joints were investigated. The optimized welding parameters were determined to be 1.0 m/min and 1300 W on the Mg side and 0.6 m/min and 1200 W on the Al side. Under these parameters, the AZ91/6061 joint exhibited a mean microhardness and average tensile strength of 83.58 MPa, with fractures occurring in the Al side weld metal by cleavage fracture.
MATERIALS TODAY COMMUNICATIONS
(2023)
Article
Engineering, Manufacturing
Himanshu Lalvani, Paranjayee Mandal, Anas Yaghi, Pedro Santos, Bernd Baufeld
Summary: The manufacture of a transition hybrid coupling using forge welding and rotary friction welding showed superior results in terms of weld interface and hardness distribution compared to electron beam welding, highlighting potential benefits of solid-state joining methods.
JOURNAL OF MANUFACTURING PROCESSES
(2022)
Article
Engineering, Civil
Jun Wu, Bin Qiang, Xiaoxuan Liao, Ling Kang, Changrong Yao, Yadong Li
Summary: The study investigated the welding residual stress (WRS) in orthotropic steel deck (OSD) with diaphragm through experiments and numerical simulations. The accuracy of WRS simulation was greatly improved by considering solid-state phase transformation (SSPT). The WRS in weld zone was significantly reduced and influenced by the diaphragm and cope hole structure.
ENGINEERING STRUCTURES
(2022)
Article
Materials Science, Multidisciplinary
Sajjad Barzegar-Mohammadi, Mohammad Haghpanahi, Mostafa Zeinoddini, Reza Miresmaeili
Summary: This paper focuses on the fatigue behavior of fillet welded patch repairs made on normalized A516 GR.70 carbon steel plates. The study finds that post-weld heat treatment and TIG-dressing do not significantly affect the fatigue life, while the latter provides the most significant fatigue improvement by altering the geometry, microstructure, and hardness of the weld toe.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Engineering, Manufacturing
Pranay Kumar Sarkar, Sashindra Kumar Kakoty
Summary: The study shows that the TIG welding process is capable of successfully producing bell metal joints, opening up new market avenues for the industry.
MATERIALS AND MANUFACTURING PROCESSES
(2022)
Article
Optics
Ruolin Wu, Yu Huang, Youmin Rong, Jiajun Xu, Quan Chen
Summary: A complete solid phase transformation model was proposed to accurately predict the welding-induced residual stress and strain of high strength steel thick plate EH40 butt joint in single-pass full penetration laser welding, which showed significant effects on the stress and strain distribution. The results of this study provide valuable insights for understanding the evolution mechanism of stress and strain in the later stage of cooling stage.
OPTICS AND LASER TECHNOLOGY
(2023)
Article
Chemistry, Physical
Michael Becker, Alexander Kuball, Amirhossein Ghavimi, Bastian Adam, Ralf Busch, Isabella Gallino, Frank Balle
Summary: Ultrasonic metal welding is applied to join crystalline aluminum alloys and amorphous bulk metallic glasses, with the metallic glass component retaining its amorphous structure in the joint and exhibiting higher joint strength than the aluminum alloy sheet.
Review
Chemistry, Physical
Gaurang R. Joshi, Vishvesh J. Badheka, Raghavendra S. Darji, Ankit D. Oza, Vivek J. Pathak, Dumitru Doru Burduhos-Nergis, Diana Petronela Burduhos-Nergis, Gautam Narwade, Gopinath Thirunavukarasu
Summary: This article reviews the joining mechanism of copper to stainless steel, emphasizing the possibility of achieving defect-free strong joints under different solid-state processing conditions. It also highlights the gaps and challenges in current research.
Article
Chemistry, Physical
Yu Li, Jia-Yi Hou, Wen-Jian Zheng, Zheng-Quan Wan, Wen-Yong Tang
Summary: A prediction model using the finite element method was established to evaluate the phase composition, residual stress, and deformation of the welded joints of Ti-6Al-4V titanium alloy. This model is significant for studying the microstructure evolution, residual stress, and deformation during welding process.
Review
Metallurgy & Metallurgical Engineering
L. R. R. Silva, E. A. S. Marques, Lucas F. M. da Silva
Summary: This review highlights several polymer-joining techniques and recent technological advances in the field, aiming to improve mechanical performance and reduce costs. Experimental works and numerical simulations have shown the validity of these techniques, while optimization processes are necessary to achieve maximum performance. Future research focuses on developing and proposing promising techniques for polymer bonding.
WELDING IN THE WORLD
(2021)
Review
Materials Science, Composites
Bala Murali Nagarajan, Manikandan Manoharan
Summary: This article provides a detailed discussion of the bonding mechanism of hybrid joints between metal and polymers. It covers various welding processes such as friction stir welding, friction stir spot joining, friction riveting, laser welding, ultrasonic welding, and induction welding. The defects and mechanical properties are analyzed, and the microstructure of different hybrid joints is reviewed.
JOURNAL OF THERMOPLASTIC COMPOSITE MATERIALS
(2023)
Article
Engineering, Manufacturing
Suo Li, Long Hu, Peiyuan Dai, Tao Bi, Dean Deng
Summary: The welding-induced residual stresses in dissimilar metal butt-welded joints between P92 steel and SUS304 stainless steel were investigated using finite element analyses and experimental measurements. Factors such as solid-state phase transformation, strain hardening, annealing effect, and thermal expansion coefficient differences were found to have significant influence on the formation of longitudinal residual stresses. The butt-welded joint with X-groove was suggested to be superior in reducing high tensile residual stress compared to the joint with single V-groove.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Materials Science, Multidisciplinary
Suo Li, Jian Li, Guangai Sun, Dean Deng
Summary: In this study, a butt-welded joint between P92 ferritic steel and SUS304 austenitic stainless steel was investigated. Finite element analyses were used to study the hardness and welding residual stress. Various factors influencing the formation of hardness and residual stress were considered, and the predicted results were in good agreement with the measurements. The effects of peak temperature, internal restraint, and differential thermal expansion were found to be decisive for the formation of residual stress.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Review
Materials Science, Multidisciplinary
Rajesh P. Verma, K. N. Pandey, Kovacs Andras, Rohit Khargotra, Tej Singh
Summary: The article reviews the difficulties and their solutions in fusion welding of aluminium alloys, particularly in gas metal arc (GMA) and gas tungsten arc (GTA) welding. The unique thermal and chemical properties of aluminium alloys make the welding process more challenging. Various techniques, such as pulsing the current and post-weld heat treatment, are recommended to improve the weld quality and joint strength. Welding dissimilar aluminium alloys presents additional difficulties, which can be overcome by adjusting the torch position and selecting a compatible filler material.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
Article
Automation & Control Systems
Dawei Zhao, Yuriy Bezgans, Nikita Vdonin, Liudmila Radionova, Vitaly Bykov
Summary: This study systematically investigates the relationship between welding process variables and welding bead geometric features, as well as optimization of welding quality. By establishing models and using the desirability function approach, suitable welding parameters are recommended to meet the conflicting demands of multiple bead geometric features.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2021)
Article
Materials Science, Multidisciplinary
Valeriy Gornyakov, Yongle Sun, Jialuo Ding, Stewart Williams
Summary: This study develops an efficient modeling approach to simulate wire arc additive manufacturing (WAAM) and rolling, providing steady-state solutions. By reducing the size of the model and applying proper constraints, the short models can achieve solutions equivalent to traditional full-size models. The study also analyzes the influential factors and implications of the strains and stresses generated by WAAM and rolling.
MODELLING AND SIMULATION IN MATERIALS SCIENCE AND ENGINEERING
(2022)
Article
Materials Science, Multidisciplinary
C. R. D'Elia, P. Carlone, J. W. Dyer, J. B. Levesque, J. Araujo de Oliveira, M. B. Prime, M. J. Roy, T. J. Spradlin, R. Stilwell, F. Tucci, A. N. Vasileiou, B. T. Watanable, M. R. Hill
Summary: This study investigates the reproducibility of the contour method for residual stress measurement through a double-blind experiment. An average residual stress field and the spatial distribution of reproducibility standard deviation are determined.
EXPERIMENTAL MECHANICS
(2022)
Article
Materials Science, Multidisciplinary
J. A. Francis
Summary: This article highlights three priority areas for development in the nuclear sector and discusses each one in detail. While these areas are conceived with the nuclear sector in mind, they are also relevant to welding in general, such as pressure vessel fabrication and piping. The intention of the article is to stimulate ideas, provoke debate, and encourage the welding community to overcome the challenges of transitioning to a low-carbon future.
SCIENCE AND TECHNOLOGY OF WELDING AND JOINING
(2022)
Article
Engineering, Multidisciplinary
Yongle Sun, Mike Smith, Thomas Dutilleul, Steve Jones
Summary: This study investigates the distortion and stress induced by electron beam welding in a low-alloy steel thick-section shell-flange structure and proposes strategies to mitigate these issues. Restraint through tack welds can effectively reduce gapping distortion, but it generates high transient tensile stress. Additionally, high residual stresses with high triaxiality occur in the weld stop region, which cannot be diminished by overlap welding or change of weld stop position.
INTERNATIONAL JOURNAL OF PRESSURE VESSELS AND PIPING
(2022)
Article
Thermodynamics
T. F. Flint, M. J. Anderson, V Akrivos, M. J. Roy, J. A. Francis, A. Vasileiou, M. C. Smith
Summary: This work applies a novel mathematical framework to describe the fusion and vapourisation state transitions in multi-component systems in the laser powder bed fusion process. The study investigates the role of vapourisation and condensation of the multi-component metallic substrate to understand the defect formation and chemical homogenisation mechanisms. The findings show that entrained vapour bubbles in chemically dissimilar flows promote greater homogenisation during condensation and collapse, and that preferential element evaporation is a non-linear function of power density.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2022)
Article
Thermodynamics
Chong Wang, Yongle Sun, Guangyu Chen, Xin Chen, Jialuo Ding, Wojciech Suder, Chenglei Diao, Stewart Williams
Summary: A three-dimensional finite element model was developed to analyze the thermal behavior in hybrid plasma transferred arc-laser additive manufacturing. The model showed good agreement with experimental data and revealed that the geometry of the melt pool is more sensitive to laser power and travel speed.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2022)
Article
Materials Science, Multidisciplinary
Valeriy Gornyakov, Yongle Sun, Jialuo Ding, Stewart Williams
Summary: The hybrid process of wire arc additive manufacturing (WAAM) and high-pressure rolling offers a solution for creating large-scale components with low residual stress and distortion. A coupled process model was developed to simulate the interaction between WAAM deposition and rolling, and its accuracy was verified by experimental results.
MATERIALS & DESIGN
(2022)
Article
Materials Science, Multidisciplinary
Rahul Unnikrishnan, Jabbar Gardy, Ben F. Spencer, Robin Kurinjimala, Avishek Dey, Vahid Nekouie, Sandeep Irukuvarghula, Ali Hassanpour, Christoph Eisenmenger-Sittner, John A. Francis, Michael Preuss
Summary: The oxidation state and surface properties of powder particles have a significant impact on the properties of powder manufactured components. In this study, a protective coating of chromium was applied to a non-stainless low alloy steel powder to prevent progressive oxidation and improve powder flowability. The effects of the coating on oxidation resistance, electrical charging, and flowability were investigated. The results showed that the chromium coating reduced oxidation and improved the flowability of the powder.
MATERIALS & DESIGN
(2022)
Article
Computer Science, Software Engineering
Thomas F. Flint, Joseph D. Robson, Gowthaman Parivendhan, Philip Cardiff
Summary: The application of high energy density photonic sources to metallic substrates leads to localised topological evolution as the interface deforms under hydrodynamic forces. Understanding the deposition of laser energy, involving multiple reflection events, and using a thermal-fluid-dynamics framework, accurate predictions of important processes can be made. laserbeamFoam, a thermal-fluid-dynamics solver with ray-tracing and Fresnel equation implementation, is introduced in this work.
Article
Engineering, Manufacturing
Gowthaman Parivendhan, Philip Cardiff, Thomas Flint, Zeljko Tukovic, Muhannad Obeidi, Dermot Brabazon, Alojz Ivankovic
Summary: This study presents a numerical model of the Laser Beam Powder Bed Fusion (PBF-LB) process that incorporates Computational Fluid Dynamics (CFD) and Discrete Element Method (DEM). The model successfully captures the particle distribution in the powder bed and the formation and dynamics of the melt pool. It considers factors such as surface tension, Marangoni convection, and recoil pressure at the metal/gas interface.
ADDITIVE MANUFACTURING
(2023)
Article
Thermodynamics
T. F. Flint, T. Dutilleul, W. Kyffin
Summary: In this work, a novel mathematical framework is used to fully describe fusion and vaporization state transitions in multi-component substrates, aiding in the understanding of thermo-capillary formation and stability during electron beam welding. The role of electron beam divergence and focal point location within the substrate is numerically investigated, revealing that the focal point location directly influences keyhole formation dynamics and leads to different keyhole structures. Additionally, a less divergent electron beam exhibits a higher penetration rate and produces a more stable thermo-capillary. The study also explores the chemical heterogeneity induced by preferential element evaporation, predicting significant manganese loss in the simulated SA508 steel substrate.
INTERNATIONAL JOURNAL OF HEAT AND MASS TRANSFER
(2023)
Article
Engineering, Multidisciplinary
D. K. Rissaki, P. G. Benardos, G. -C Vosniakos, M. C. Smith, A. N. Vasileiou
Summary: The study developed two Artificial Neural Network (ANN) ensemble models to predict through-thickness residual stress profiles in Weld Centre Line (WCL) using residual stress measurements of girth welded austenitic stainless-steel pipes. One model was developed for axial and the other for hoop residual stress prediction. The models' inputs included the pipe radius to thickness ratio, thickness, heat input, and normalised through-thickness position. The models' performance was evaluated by a test set and sensitivity studies.
INTERNATIONAL JOURNAL OF PRESSURE VESSELS AND PIPING
(2023)
Article
Engineering, Multidisciplinary
Zeyuan Miao, Lee Margetts, Anastasia N. Vasileiou, Hujun Yin
Summary: This study developed a workflow that automates all the steps involved in generating, calculating, and extracting results from finite element simulations to quickly develop machine learning surrogate models for predicting post-weld residual stresses. The developed workflow was validated using a case study on a single weld sample, and the predictive performance of an Artificial Neural Network based surrogate model was investigated. The relative root mean square error of the predictive surrogate model for the test dataset was 0.0024.
INTERNATIONAL JOURNAL OF PRESSURE VESSELS AND PIPING
(2023)
Article
Engineering, Multidisciplinary
Foroogh Hosseinzadeh, Behrooz Tafazzoli-Moghaddam, Ho Kyeom Kim, Peter John Bouchard, Vasileios Akrivos, Anastasia N. Vasileiou, Mike Smith
Summary: This paper presents the characterization of residual stress in two thin-walled austenitic girth welded pipes using two independent measurement techniques, the contour method and neutron diffraction. The results obtained from these techniques are compared and the specific characteristics of residual stress distribution are discussed.
INTERNATIONAL JOURNAL OF PRESSURE VESSELS AND PIPING
(2023)
Article
Engineering, Manufacturing
Vasileios Akrivos, Ondrej Muransky, Lionel Depradeux, Michael C. Smith, Anastasia Vasileiou, Viorel Deaconu, Priyesh Kapadia
Summary: This report discusses the activities of a European network in developing accurate experimental and numerical methods to assess residual stresses in structural weldments. Through neutron diffraction measurements using different instruments, the network obtained a large database to generate reliable mean profiles and establish the systematic uncertainty associated with this non-destructive technique. The study provides valuable insights into the real-world variability of diffraction-based residual stress measurements and serves as a reliable benchmark for other measurement methods.
JOURNAL OF MANUFACTURING AND MATERIALS PROCESSING
(2022)