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
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
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)
Article
Metallurgy & Metallurgical Engineering
Joerg Bellmann, Sebastian Schettler, Sebastian Schulze, Markus Wagner, Jens Standfuss, Martina Zimmermann, Eckhard Beyer, Christoph Leyens
Summary: The conventional fusion welding of dissimilar metals is often limited by the different thermo-physical properties of the joining partners, leading to the formation of brittle intermetallic phases (IMC). Utilizing a pressure welding process like magnetic pulse welding (MPW) can significantly reduce the risk of IMCs. Two strategies are presented in the research to reduce the energy input during MPW and increase the tool coil lifetime, including the introduction of a reactive nickel interlayer and a novel process monitoring system for analyzing characteristic light emission.
WELDING IN THE WORLD
(2021)
Article
Automation & Control Systems
Yingzi Chen, Huaiqing Zhang, Hao Wu, Wenxiong Peng
Summary: This paper applies magnetic pulse welding to join AA1060/TC4 sheets and investigates the electromagnetic mechanism, dynamic characteristics, and the influence of process parameters on the welding effect. The experimental results show that 1060 aluminum and TC4 titanium sheets can be effectively joined, forming a defect-free wavy interface, under specific discharge energy and standoff distance.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2022)
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
Wentao Zhang, Yuhua Chen, Jilin Xie, Timing Zhang, Shanlin Wang, Xiao Song, Limeng Yin
Summary: Magnetic pulse welding (MPW) is used to join dissimilar metals with no mutual solubility, such as Al/Ta. The Al/Ta interface was characterized using SEM, TEM, and EDS, revealing the formation of different types of interfaces due to the inhomogeneity of the MPW process. The coexistence of nanocrystalline/amorphous bi-phase interface and continuous intermetallic compound (IMC) suggests that high strain is the main cause of interfacial amorphous.
JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T
(2023)
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
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
Materials Science, Multidisciplinary
Mingfeng Li, Wu Tao, Jiazhi Zhang, Yanjun Wang, Shanglu Yang
Summary: This work proposes an innovative hybrid resistance spot-laser welding process for joining aluminum to steel. The process first conducts resistance spot welding of aluminum and steel and then follows with laser spot welding. Through innovative electrode structure design, the welding current distribution and weld structure are optimized to achieve a thin and uniform intermetallic layer. The process also changes the faying interface morphology and improves the tensile-shear load and energy absorption of the joints.
MATERIALS & DESIGN
(2022)
Article
Engineering, Manufacturing
Hrishikesh Das, Piyush Upadhyay
Summary: The implementation of a stationary shoulder in dissimilar joints of Al-steel and Al-CFRP using friction stir assisted scribe technology (FaST) resulted in viable joint strength and improved surface roughness. Interruption lap shear tests and computational modeling showed that joint failure typically occurs in the aluminum sheet, with a similar fracture path observed in both Al-steel and Al-CFRP joints.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2021)
Review
Mechanics
Francesco Lambiase, Frank Balle, Lucian-Attila Blaga, Fengchao Liu, Sergio T. Amancio-Filho
Summary: The adoption of multi-material lightweight structures and friction-based joining processes has shown significant potential in improving fuel efficiency and enhancing the electrification of transportation systems. This review article provides an overview of five promising friction-based joining processes and discusses their advantages, applicable materials, and performance under various environmental conditions. The paper highlights the main similarities and differences among the joining processes and addresses the knowledge gaps that need to be filled to further advance the joining process for industrial applications.
COMPOSITE STRUCTURES
(2021)
Article
Materials Science, Multidisciplinary
Puquan Wang, Daolun Chen, Yunqi Yan, Xinwei She, Bo Feng, Yang Ran, He Peng, Dongyang Li, Xianquan Jiang
Summary: In this study, the microstructural changes and bonding characteristics of Al6061-Q355 steel dissimilar welded joints were characterized via electromagnetic pulse welding (EMPW). Different zones were identified on the collision surface, each with unique features representing various bonding mechanisms influenced by impact energy, pressure, and velocities.
Article
Engineering, Manufacturing
M-N Avettand-Fenoel, T. Sapanathan, T. Pirling, G. Racineux, A. Simar, J-M Drezet
Summary: Residual stresses in a dissimilar AA1050-DP450 steel magnetic pulse weld were investigated using neutron diffraction for the first time. Tensile residual stresses were observed in the Al sheet and compressive residual stresses in the steel sheet, with different distributions at the joint interface. The asymmetrical shape of the rectangular joint line resulted in lower magnitude of residual stresses along the short side of the weld.
JOURNAL OF MANUFACTURING PROCESSES
(2021)
Article
Engineering, Mechanical
Alexander Schowtjak, Robin Schulte, Till Clausmeyer, Richard Ostwald, A. Erman Tekkaya, Andreas Menzel
Summary: The free and open source software tool ADAPT is presented for the inverse parameter identification of constitutive material models and applied in conjunction with Finite Element simulations. Different types of input data, such as forces and field data, are considered within a multi-objective optimization scheme. By applying various models, the tool demonstrates a wide range of parameter identification applications.
INTERNATIONAL JOURNAL OF MECHANICAL SCIENCES
(2022)
Article
Green & Sustainable Science & Technology
Andre Schulze, Oliver Hering, A. Erman Tekkaya
Summary: By utilizing a new process chain, bent components and deep drawn cups are produced directly from aluminum chips without melting, offering a resource-efficient alternative for the production of aluminum sheet products. The properties and forming capabilities of the chip-based sheets are comparable to those made from conventional cast billets, making them a viable option for further plastic forming operations.
INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING-GREEN TECHNOLOGY
(2022)
Article
Engineering, Industrial
Hamed Dardaei Joghan, Marlon Hahn, Jan T. Sehrt, A. Erman Tekkaya
Summary: Deep drawing dies face challenges in terms of strength and surface finish. Techniques such as laser metal deposition and post-processing are applied to improve the surface finish. A semi-analytical model is developed for selecting suitable sheet combinations. The new rapid prototyping process offers flexibility for complex die geometries, and the feasibility of the new manufacturing routes is evaluated through deep drawing experiments.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2022)
Editorial Material
Engineering, Industrial
Kunpeng Zhu, Yongjie Jessica Zhang, Robert Gao, Markus Bambach, Erman Tekkaya
JOURNAL OF MATERIALS PROCESSING TECHNOLOGY
(2022)
Article
Engineering, Manufacturing
Tanmoy Rakshit, Johannes Gebhard, Oliver NapieralanAff, Felix Kolpak, Andre Schulze, Oliver Hering, A. Erman Tekkaya
Summary: Composite components offer improved product properties, resource efficiency, and product diversity by combining different materials. The study investigates various failure types and successfully increases the encapsulation length. The use of anisotropic sheet material enhances form fit and bond strength in draw-forged hybrid components.
INTERNATIONAL JOURNAL OF MATERIAL FORMING
(2022)
Article
Automation & Control Systems
Hamed Dardaei Joghan, Marlon Hahn, A. Erman Tekkaya
Summary: Metal-laminated tooling using laser metal deposition (LMD) is used to reduce the stair step effect in a bending die. The effect of preheating on the surface quality and mechanical properties of the die is analyzed. Preheating increases surface roughness but has limited effect on reducing residual stress. The functionality of the manufactured tools is proven through bending tests.
INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Robin Gitschel, Oliver Hering, Andre Schulze, A. Erman Tekkaya
Summary: The evolution of ductile damage in cold forging can be controlled without changing the geometry of the produced part by adjusting process parameters and introducing counterpressure. The load path-dependent damage can be controlled by varying extrusion strain and shoulder opening angle. Introducing counterpressure helps decrease triaxiality in the forming zone without affecting the products' geometries.
JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING-TRANSACTIONS OF THE ASME
(2023)
Article
Engineering, Industrial
A. E. Tekkaya, P. Groche, B. L. Kinsey, Z. G. Wang
Summary: Stress superposition is the process of adding stresses on an existing forming process to enhance metal forming processes and formed components. It can lead to improvements in reducing forming force, increasing formability, and tailoring physical properties. This article provides an extensive analysis and classification of current stress superposition methods, and proposes future opportunities for designing new forming processes through utilization of stress superposition.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Industrial
Johannes Gebhard, Andre Schulze, Till Clausmeyer, A. Erman Tekkaya
Summary: This paper introduces a novel continuous extrusion process which enables constant material flow at the die exit and reduces scrap. The process combines direct and indirect hot extrusion with a stationary valve. The challenge lies in designing the valve and related parameters to ensure a constant profile speed. Model experiments demonstrate the unique material distribution in the profile during continuous extrusion. Experimental results with aluminum show the functionality of the valve. Compared to conventional extrusion, the weld strength can be doubled while the ram forces are increased by 70%.
CIRP ANNALS-MANUFACTURING TECHNOLOGY
(2023)
Article
Engineering, Manufacturing
Stephan Rosenthal, Marlon Hahn, A. Erman Tekkya
Summary: The deep drawability of additively manufactured stainless steel sheets with a core structure is investigated and it is shown that the sheets have good formability. Numerical analysis and experimental validation of the deep drawing process are conducted, revealing that the main failure mode is fracture of the face sheets. The core structure remains intact, ensuring structural integrity of the parts after the deep drawing process. A modified Siebel's method can reasonably predict the process forces and a process window diagram is derived.
INTERNATIONAL JOURNAL OF MATERIAL FORMING
(2023)
Correction
Engineering, Manufacturing
Stephan Rosenthal, Marlon Hahn, A. Erman Tekkaya
INTERNATIONAL JOURNAL OF MATERIAL FORMING
(2023)
Article
Engineering, Industrial
F. Weber, Y. Lu, F. J. Peterschilka, M. Hahn, A. E. Tekkaya
Summary: This study investigates the electromagnetic joining of aluminum alloy 6082 and thermoplastic polycarbonate tubes. The results demonstrate a significant impact of the diameter ratio on the joint strength. Increasing the ratio of inner to outer diameter can greatly enhance the transferable push-out force, while lower ratios may lead to macroscopic cracks that limit the transferable forces.
ADVANCES IN INDUSTRIAL AND MANUFACTURING ENGINEERING
(2023)
Article
Engineering, Industrial
Joshua Grodotzki, Benedikt Tobias Mueller, Erman Tekkaya
Summary: There is a lack of a universal Augmented Reality platform for manufacturing engineering and education fields. This contribution developed a platform that allows instructors to manage online courses and teaching materials. In addition, a new application was created for iOS and Android systems to display objects and provide additional information. The platform also includes a novel storage format to reduce the storage size of models and improve performance on smartphones. Various 3D file formats and results from FEM software can be imported and converted for analysis. The app enables users to view, inspect, and interact with models and animations.
ADVANCES IN INDUSTRIAL AND MANUFACTURING ENGINEERING
(2023)
Article
Engineering, Manufacturing
Mike Kamaliev, Jan Flesch, Joshua Grodotzki, A. Erman Tekkaya
Summary: The isothermal high temperature pneumoforming process for forming tubes at constant elevated temperatures by means of internal pressure was investigated using a ferritic and a martensitic stainless steel. Material characterization was performed at the temperature and strain rate of the process, and a new method for quantifying thermal softening was presented. Numerical models were validated and used to study the influence of process parameters on the final part geometry. Process windows were derived based on internal pressure and die edge length, and good agreement with experiments was observed.
INTERNATIONAL JOURNAL OF MATERIAL FORMING
(2023)
Article
Materials Science, Multidisciplinary
Mathilde Laurent-Brocq, Lola Lilensten, Clemence Pinot, Andre Schulze, Amandine Duchaussoy, Julie Bourgon, Eric Leroy, A. Erman Tekkaya
Summary: Solid-state recycling of metallic alloys is a promising alternative method for reducing CO2-emission compared to remelting. This study quantifies and localizes oxygen contamination at each step of the process, revealing an increase in oxygen content and the formation of oxide layers. Alloying elements are involved in oxidation, resulting in a complex network of oxides with thin thickness and low density. Tuning processing parameters is a promising approach to limit oxidation and improve chip welding.