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Advances in Dissimilar Metal Joining and Welding
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Advances in Dissimilar Metal Joining and Welding

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 30 June 2025 | Viewed by 7219

Special Issue Editors

Dr. Daniel F.O. Braga

E-Mail Website
Guest Editor
Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), University of Porto, 4200-465 Porto, Portugal
Interests: dissimilar joining; structural integrity; friction stir welding; fatigue; fracture
Dr. Sérgio Tavares

E-Mail Website
Guest Editor
Department of Mechanical Engineering, University of Aveiro, 3810-193 Aveiro, Portugal
Interests: structural integrity; computational mechanics; fracture mechanics; fatigue; digital-twins

Special Issue Information

Dear Colleagues,

Dissimilar material welding holds immense relevance in contemporary manufacturing due to its pivotal role in integrating diverse materials to meet specific engineering requirements. As industries increasingly demand lighter, stronger, and more versatile components, dissimilar material welding facilitates the construction of advanced structures and assemblies. However, it poses unique challenges stemming from the inherent differences in physical properties, thermal expansion coefficients, and metallurgical behaviors among dissimilar materials. Achieving robust welds while minimizing distortion, residual stresses, and intermetallic compound formation remains a daunting task. Moreover, ensuring the long-term structural integrity and reliability of dissimilar weld joints under varying operating conditions further compounds the challenges. Addressing these complexities requires interdisciplinary research efforts, innovative welding techniques, and a comprehensive understanding of material science and engineering principles, highlighting the significance of ongoing exploration and advancements in this field.

The Journal of Manufacturing and Materials Processing presents a Special Issue focused on dissimilar metal joining and welding. This Special Issue examines the latest advancements and practical implications in joining different metals, metal polymer joints, and metal composite joints, crucial across industries like the automotive, aerospace, and electronics industries.

Aligned with the journal's scope, this Special Issue addresses the fundamental challenges and innovative solutions in manufacturing processes and materials engineering. Contributors explore diverse methods, including friction stir welding, laser welding, ultrasonic welding, and adhesive bonding, tackling issues such as metallurgical compatibility, thermal management, and joint integrity.

Through experimental manufacturing trials, material and joint mechanical characterization, numerical modeling, and advanced experimental characterization of dissimilar joints and structures, this Special Issue fosters scientific discourse and practical insights essential for developing efficient and sustainable dissimilar metal joining techniques. It serves as a platform to bridge theoretical understanding with real-world applications, facilitating the advancement of manufacturing technologies and materials science.

Dr. Daniel F.O. Braga
Dr. Sérgio Tavares
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • dissimilar joining
  • welding
  • intermetallics
  • bonding mechanisms
  • structural integrity
  • fatigue
  • fracture
  • corrosion

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Published Papers (6 papers)

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Research

18 pages, 7106 KiB  
Article
Hybrid Tool Holder by Laser Powder Bed Fusion of Dissimilar Steels: Towards Eliminating Post-Processing Heat Treatment
by Faraz Deirmina, Ville-Pekka Matilainen and Simon Lövquist
J. Manuf. Mater. Process. 2025, 9(2), 64; https://doi.org/10.3390/jmmp9020064 - 18 Feb 2025
Viewed by 362
Abstract
The hybridization of additive manufacturing (AM) with conventional manufacturing processes in tooling applications allows the customization of the tool. Examples include weight reduction, improving the vibration-dampening properties, or directing the coolant to the critical zones through intricate conformal cooling channels aimed at extending [...] Read more.
The hybridization of additive manufacturing (AM) with conventional manufacturing processes in tooling applications allows the customization of the tool. Examples include weight reduction, improving the vibration-dampening properties, or directing the coolant to the critical zones through intricate conformal cooling channels aimed at extending the tool life. In this regard, metallurgical challenges like the need for a post-processing heat treatment in the AM segment to meet the thermal and mechanical properties requirements persist. Heat treatment can destroy the dimensional accuracy of the pre-manufactured heat-treated wrought segment, on which the AM part is built. In the case of dissimilar joints, heat treatment may further impact the interface properties through the ease of diffusional reactions at elevated temperatures or buildup of residual stresses at the interface due to coefficient of thermal expansion (CTE) mismatch. In this communication, we report on the laser powder bed fusion (L-PBF) processing of MAR 60, a weldable carbon-free maraging powder, to manufacture a hybrid tool holder for general turning applications, comprising a wrought segment in 25CrMo4 low-alloy carbon-bearing tool steel. After L-PBF process optimization and manipulation, as-built (AB) MAR 60 steel was characterized with a hardness and tensile strength of ~450 HV (44–45 HRC) and >1400 MPa, respectively, matching those of pre-manufactured wrought 25CrMo4 (i.e., 42–45 HRC and 1400 MPa). The interface was defect-free with strong metallurgical bonding, showing slight microstructural and hardness variations, with a thickness of less than 400 µm. The matching strength and high Charpy V-notch impact energy (i.e., >40 J) of AB MAR 60 eliminate the necessity of any post-manufacturing heat treatment in the hybrid tool. Full article
(This article belongs to the Special Issue Advances in Dissimilar Metal Joining and Welding)
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14 pages, 3064 KiB  
Article
Ring Beam Modulation-Assisted Laser Welding on Dissimilar Materials for Automotive Battery
by Se-Hoon Choi, Jong-Hyun Kim and Hae-Woon Choi
J. Manuf. Mater. Process. 2025, 9(2), 28; https://doi.org/10.3390/jmmp9020028 - 21 Jan 2025
Viewed by 855
Abstract
This paper investigates Ring Beam Modulation-assisted Laser (RBML) welding as a novel approach for joining dissimilar materials, specifically aluminum and copper, which are essential in high-performance applications such as electric vehicle batteries and aerospace components. The study aims to address challenges such as [...] Read more.
This paper investigates Ring Beam Modulation-assisted Laser (RBML) welding as a novel approach for joining dissimilar materials, specifically aluminum and copper, which are essential in high-performance applications such as electric vehicle batteries and aerospace components. The study aims to address challenges such as thermal mismatches, brittle intermetallic compounds, and structural defects that hinder traditional welding methods. The research combines experimental and computational analyses to evaluate the impact of heat input distributions and laser modulation parameters on weld quality and strength. Three welding cases are compared: fixed center beam with variable ring beam outputs, variable center beam with fixed ring outputs, and a wobble-mode beam to enhance interfacial bonding. Computational modeling supports the optimization process by simulating heat flows and material responses, exploring various shape factors, and guiding parameter selection. Key findings include a nonlinear relationship between heat input and welding strength across the cases. Case 1 demonstrates improved weld strength with higher ring beam input, while Case 2 achieves excellent reliability with relatively lower inputs. Case 3 introduces wobble welding, yielding superior resolution and consistent weld quality. These results confirm that precise ring beam modulation enhances weld reliability, minimizes thermal distortions, and optimizes energy consumption. The manuscript advances the state of knowledge in laser welding technology by demonstrating a scalable, energy-efficient method for joining dissimilar materials. This contribution supports the fabrication of lightweight, high-reliability assemblies, paving the way for innovative applications in the automotive, medical, aerospace, and shipbuilding industries. Full article
(This article belongs to the Special Issue Advances in Dissimilar Metal Joining and Welding)
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14 pages, 9357 KiB  
Article
Design and Development of a Bespoke Rotary Friction Welding Machine in Exploration of Joining Dissimilar Materials for Nuclear Applications
by Michail Dellepiane, Laurie Da Silva and Athanasios Toumpis
J. Manuf. Mater. Process. 2025, 9(1), 27; https://doi.org/10.3390/jmmp9010027 - 18 Jan 2025
Viewed by 913
Abstract
Rotary friction welding is a solid-state welding process that can manufacture high-integrity joints between similar and dissimilar materials with short weld times. However, access to expensive and complex industrial-grade friction welding machines is not always possible. This study explores the design process and [...] Read more.
Rotary friction welding is a solid-state welding process that can manufacture high-integrity joints between similar and dissimilar materials with short weld times. However, access to expensive and complex industrial-grade friction welding machines is not always possible. This study explores the design process and functionality of a laboratory-scale friction welding setup following the fundamentals of large-scale machinery. The proposed setup is designed to be easily manufactured, employing the use of a calibrated drill press and load cell, thus ensuring welding parameters such as rotational speed and applied axial load are monitored. The decision to investigate rotary friction welding of aluminium bronze Ca104 to austenitic stainless steel AISI316 was taken to explore the limitations of this bespoke friction welding machine for prospective applications in the nuclear energy sector. The workpieces were friction welded at four sets of rotational speeds with constant friction and forging pressures. The microstructural evolution and mechanical properties of the dissimilar material welds were investigated via optical and scanning electron microscopy with energy dispersive spectroscopy, 4-point bend testing and microhardness measurements. Results show a change in the hardness along the weld interface and evidence of metallic diffusion between the dissimilar materials, demonstrating the successful application of the small-scale experimental setup. Full article
(This article belongs to the Special Issue Advances in Dissimilar Metal Joining and Welding)
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12 pages, 21287 KiB  
Article
Microstructure, Physical-Mechanical, and Magnetic Characteristics of a Butt-Welded Joint Obtained by Rotary Friction Welding Technology of Bimetallic Pipe
by Evgeniia Putilova, Kristina Kryucheva, Ivan Kamantsev and Elena Priymak
J. Manuf. Mater. Process. 2024, 8(6), 271; https://doi.org/10.3390/jmmp8060271 - 28 Nov 2024
Viewed by 835
Abstract
The development of technology, including in the oil and gas industry, necessitates the creation of materials with special sets of properties, such as high strength characteristics combined with corrosion resistance. One such material is bimetallic pipe, but we are faced with the problem [...] Read more.
The development of technology, including in the oil and gas industry, necessitates the creation of materials with special sets of properties, such as high strength characteristics combined with corrosion resistance. One such material is bimetallic pipe, but we are faced with the problem of creating extended structures and obtaining high-quality butt-welded joints of such industrial bimetallic pipes. The microstructure in different parts of the thermomechanically influenced zone of a butt-welded joint of a bimetallic pipe obtained by rotary friction welding (RFW) was investigated by optical and electron microscopy methods. It was established that during rotary friction welding of the bimetallic pipe in standard mode, one metal flowed into the zone of another. This could be explained by the different plastic properties of the steels that made up the bimetal, which must be taken into account in future welding. Standard RFW mode did not result in the formation of a high-quality weld; defects and discontinuities were observed in the joint area. The maximum hardness values were observed directly in the weld joint. It is concluded that rotary friction welding can be used as a welding technology for bimetallic pipes, but the most attention should be paid to the welding mode to obtain a high-quality butt-welded joint. Full article
(This article belongs to the Special Issue Advances in Dissimilar Metal Joining and Welding)
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18 pages, 12668 KiB  
Article
The Mechanical Properties of a Transient Liquid Phase Diffusion Bonded SSM-ADC12 Aluminum Alloy with a ZnAl4Cu3 Zinc Alloy Interlayer
by Chaiyoot Meengam, Yongyuth Dunyakul and Dech Maunkhaw
J. Manuf. Mater. Process. 2024, 8(5), 184; https://doi.org/10.3390/jmmp8050184 - 23 Aug 2024
Viewed by 1142
Abstract
In this study, the mechanical properties of SSM-ADC12 aluminum alloy specimens with a ZnAl4Cu3 zinc alloy interlayer were observed after Transient Liquid Phase Diffusion Bonding (TLPDB), a welding process conducted in a semi-solid state. The purpose of the experiment was to study how [...] Read more.
In this study, the mechanical properties of SSM-ADC12 aluminum alloy specimens with a ZnAl4Cu3 zinc alloy interlayer were observed after Transient Liquid Phase Diffusion Bonding (TLPDB), a welding process conducted in a semi-solid state. The purpose of the experiment was to study how the following parameters—bonding temperature (400, 430, 460, 490, and 520 °C), bonding time (60, 90, and 120 min), and thickness of the ZnAl4Cu3 zinc alloy (0.5, 1.0, and 2.0 mm)—affect the mechanical properties and the types of defects that formed. The results show that the bonding strength varied significantly with different parameters following the TLPDB process. A maximum bonding strength of 32.21 MPa was achieved at a bonding temperature of 490 °C, with 20 min of bonding and a ZnAl4Cu3 zinc alloy layer that was 2.0 mm thick. Conversely, changing the welding parameters influenced the bonding strength. A minimum bonding strength of 2.73 MPa was achieved at a bonding temperature of 400 °C, with a bonding time of 90 min and a ZnAl4Cu3 zinc alloy interlayer that was 2.0 mm thick. The Vickers microhardness results showed that the bonded zone had a lower hardness value compared to the base materials (BMs) of the SSM-ADC12 aluminum alloy (86.60 HV) and the ZnAl4Cu3 zinc alloy (129.37 HV). The maximum hardness was 83.27 HV, which resulted from a bonding temperature of 520 °C, a bonding time of 90 min, and a ZnAl4Cu3 zinc alloy that was 2.0 mm thick. However, in the near interface, the hardness value increased because of the formation of MgZn2 intermetallic compounds (IMCs). The fatigue results showed that the stress amplitude was 31.21 MPa in the BMs of the SSM-ADC12 aluminum alloy and 20.92 MPa in the material that results from this TLPDB process (TLPDB Material) when the limit of cyclic loading exceeded 106 cycles. Microstructural examination revealed that transformation from a β-eutectic Si IMC recrystallization structure to η(Zn–Al–Cu) and β(Al2Mg3Zn3) IMCs occurred. A size reduction to a width of 6–11 µm and a length of 16–44 µm was observed via SEM. Finally, voids or porosity and bucking defects were found in this experiment. Full article
(This article belongs to the Special Issue Advances in Dissimilar Metal Joining and Welding)
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15 pages, 5968 KiB  
Article
High-Precision Integration of Optical Sensors into Metallic Tubes Using Rotary Swaging: Process Phenomena in Joint Formation
by Nassr Al-Baradoni, Philipp Heck and Peter Groche
J. Manuf. Mater. Process. 2024, 8(2), 60; https://doi.org/10.3390/jmmp8020060 - 15 Mar 2024
Cited by 1 | Viewed by 1924
Abstract
A novel process design for the damage-free and highly accurate positional integration of an optical multi-axial force sensor into a hollow tube by means of rotary swaging is introduced. Numerical simulations reveal the relevant process phenomena of thin disc joining inside a pre-toothed [...] Read more.
A novel process design for the damage-free and highly accurate positional integration of an optical multi-axial force sensor into a hollow tube by means of rotary swaging is introduced. Numerical simulations reveal the relevant process phenomena of thin disc joining inside a pre-toothed hollow tube and help us to find an optimal process design. Experimental trials show the significant effect of the axial material flow and the number of tools on the rotary swaging process. By taking these effects into account, successful form- and force-fit joining of the sensor carrying discs into the tube can be achieved. Successful joining of an optical sensor for bending force and torque measurement shows hysteresis-free sensory behavior and thus backlash-free joining of the sensor carrier discs. The paper concludes with a presentation of the results of a numerical study on a potential closed-loop approach to the joining process. Full article
(This article belongs to the Special Issue Advances in Dissimilar Metal Joining and Welding)
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