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Advanced Welding Processes, Additive Manufacturing and Numerical Models
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Advanced Welding Processes, Additive Manufacturing and Numerical Models

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

Deadline for manuscript submissions: closed (1 October 2024) | Viewed by 17764

Special Issue Editor

Dr. Hui Huang

E-Mail Website
Guest Editor
School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai 200240, China
Interests: welding design; simulation; engineering software
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Welding and additive manufacturing are key technologies in the modern manufacturing industry that have increasing needs relating to high-quality products, high-volume deposition, and high-temperature application. New type of materials and structures, such as functionally graded materials and lattice structures, can be fabricated by additive manufacturing which is superior to traditional processes. Advanced welding processes and additive manufacturing, as well as their digital twins, will greatly contribute to manufacturing technology and the process development of materials.

This Special Issue aims to highlight the latest progress on the welding process and additive manufacturing development towards the fabrication of new structures, the innovation of functional materials, and the optimization of manufacturing processes. Full-length research articles on welding technology development, weld consumables, powder material, additive manufacturing process, numerical modeling, and process monitoring and control, among other things, are welcome. The world’s leading experts in the field of welding and additive manufacturing will be invited to submit their findings. Accepted papers will be open access for the whole research community in order to increase the visibility of their innovative research findings.

Dr. Hui Huang
Guest Editor

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 semimonthly 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

  • welding
  • additive manufacturing
  • process monitoring
  • modeling

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Related Special Issue

Published Papers (10 papers)

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Research

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18 pages, 4354 KiB  
Article
Modeling of Tensile Stress Distribution Considering Anisotropy of Mechanical Properties of Thin-Walled AlSi10Mg Samples Obtained by Selective Laser Melting
by Sergey N. Grigoriev, Nikita Yu. Nikitin, Aleksander Frolov, Petr Shapovalov, Anton Medeltsev, Mikhail Voronov, Roman Khmyrov, Idarmach Idarmachev and Pavel Peretyagin
J. Manuf. Mater. Process. 2024, 8(5), 235; https://doi.org/10.3390/jmmp8050235 - 20 Oct 2024
Viewed by 807
Abstract
The work that is being presented demonstrates that there is a critical point at which the engineering stress–strain diagram’s elastic–plastic region transitions to yield and fracture stresses. This transition is demonstrated using thin-walled specimens made using selective laser melting technology from high-strength aluminum [...] Read more.
The work that is being presented demonstrates that there is a critical point at which the engineering stress–strain diagram’s elastic–plastic region transitions to yield and fracture stresses. This transition is demonstrated using thin-walled specimens made using selective laser melting technology from high-strength aluminum alloys (AlSi10Mg) that have undergone preliminary heat treatment. It was discovered that the strain-hardening coefficient, which was determined in the section from yield strength to fracture strength, and the critical point have a highly statistically significant association (0.83 by Spearman and 0.93 by Pearson). It was possible to derive a regression equation that connected the strain-hardening coefficient with the crucial transition point. The type of stress distribution in the elastic–plastic region changes (the Weibull distribution changes to a normal distribution) as the plasticity of the thin-walled samples increases. Additionally, the contribution of the probability density of the stress distribution described by the Cauchy distribution increases in a mode near the point at which the probability density of the fracture increases. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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9 pages, 4839 KiB  
Communication
Dissimilar Welding of Thick Ferritic/Austenitic Steels Plates Using Two Simultaneous Laser Beams in a Single Pass
by Fabio Giudice, Severino Missori and Andrea Sili
J. Manuf. Mater. Process. 2024, 8(4), 134; https://doi.org/10.3390/jmmp8040134 - 27 Jun 2024
Cited by 1 | Viewed by 761
Abstract
Dissimilar welds between ferritic and austenitic stainless steels are widely used in industrial applications. Taking into account the issues inherent to arc welding, such as the high heat input and the need to carry out multiple passes in the case of thick plates, [...] Read more.
Dissimilar welds between ferritic and austenitic stainless steels are widely used in industrial applications. Taking into account the issues inherent to arc welding, such as the high heat input and the need to carry out multiple passes in the case of thick plates, a procedure with two simultaneous laser beams (working in a single pass) and consumable inserts as filler metal has been considered. Particular attention was paid to the choice of the filler metal (composition and amount), as well as welding parameters, which are crucial to obtain the right dilution necessary for a correct chemical composition in the weld zone. The first experimental investigations confirmed the achievement of a good weldability of the dissimilar pair ASTM A387 ferritic/AISI 304L austenitic steel, having ascertained that the microstructure of the weld zone is austenitic with a little amount of residual primary ferrite, which is the best condition to minimize the risk of hot cracking. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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15 pages, 8460 KiB  
Article
Development of Hot-Wire Laser Additive Manufacturing for Dissimilar Materials of Stainless Steel/Aluminum Alloys
by Keita Marumoto, Takahiro Horai, Daiji Morita, Chisako Oda, Takafumi Fujii, Takashi Yuzawa, Ryogo Koba and Motomichi Yamamoto
J. Manuf. Mater. Process. 2024, 8(3), 93; https://doi.org/10.3390/jmmp8030093 - 30 Apr 2024
Viewed by 1124
Abstract
The formation of brittle intermetallic compounds (IMCs) at the interface between dissimilar materials causes considerable problems. In this study, a multi-material additive manufacturing technique that employs a diode laser and the hot-wire method was developed for stainless steel/aluminum alloys. An Al-Mg aluminum alloy [...] Read more.
The formation of brittle intermetallic compounds (IMCs) at the interface between dissimilar materials causes considerable problems. In this study, a multi-material additive manufacturing technique that employs a diode laser and the hot-wire method was developed for stainless steel/aluminum alloys. An Al-Mg aluminum alloy filler wire (JIS 5183-WY) was fed on an austenitic stainless-steel plate (JIS SUS304) while varying the laser power and process speed and using paste-type flux and flux-cored wire. The effects of laser power and process speed on phenomena during manufacturing and IMC formation were investigated. Finally, the wall-type multilayer specimens were fabricated under optimized conditions. The suppression of IMC formation to a thickness of less than 2 μm was achieved in the specimens, along with a high interfacial strength of over 120 MPa on average. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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13 pages, 7141 KiB  
Article
Selection of Welding Conditions for Achieving Both a High Efficiency and Low Heat Input for Hot-Wire Gas Metal Arc Welding
by Keita Marumoto, Akira Fujinaga, Takeshi Takahashi, Hikaru Yamamoto and Motomichi Yamamoto
J. Manuf. Mater. Process. 2024, 8(2), 82; https://doi.org/10.3390/jmmp8020082 - 18 Apr 2024
Cited by 1 | Viewed by 1240
Abstract
This study presents a new gas metal arc welding (GMAW) technique that achieves both high efficiency and low heat input using a hybridization of the hot-wire method. The optimal combination of welding speed and welding current conditions was investigated using a fixed hot-wire [...] Read more.
This study presents a new gas metal arc welding (GMAW) technique that achieves both high efficiency and low heat input using a hybridization of the hot-wire method. The optimal combination of welding speed and welding current conditions was investigated using a fixed hot-wire feeding speed of 10 m/min on a butt joint with a V-shaped groove using 19 mm thick steel plates. Molten pool stability and defect formation were observed using high-speed imaging and cross-sectional observations. The power consumption and heat input were predicted prior to welding and measured in the experiments. The results indicate that a combination of a welding current of 350–500 A and welding speed of 0.3–0.7 m/min is optimal to avoid defect formation and molten metal precedence using three or four passes. The higher efficiency and lower heat input achieved by hot-wire GMAW results in a weld metal of adequate hardness, narrower heat-affected zone, smaller grain size at the fusion boundary, and lower power consumption than those obtained using tandem GMAW and high-current GMAW. Based on the experimental results, a single bevel groove, which is widely used in construction machinery welding joints, was welded using hot-wire GMAW, and we confirmed that the welding part could be welded in six passes, whereas eight passes were required with GMAW only. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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27 pages, 6236 KiB  
Article
Comprehensive Distortion Analysis of a Laser Direct Metal Deposition (DMD)-Manufactured Large Prototype Made of Soft Martensitic Steel 1.4313
by Indira Dey, Raphael Floeder, Rick Solcà, Timo Schudeleit and Konrad Wegener
J. Manuf. Mater. Process. 2024, 8(2), 78; https://doi.org/10.3390/jmmp8020078 - 16 Apr 2024
Viewed by 1254
Abstract
Additive manufacturing (AM) by using direct metal deposition (DMD) often causes erratic distortion patterns, especially on large parts. This study presents a systematic distortion analysis by employing numerical approaches using transient–thermal and structural simulations, experimental approaches using tomography, X-ray diffraction (XRD), and an [...] Read more.
Additive manufacturing (AM) by using direct metal deposition (DMD) often causes erratic distortion patterns, especially on large parts. This study presents a systematic distortion analysis by employing numerical approaches using transient–thermal and structural simulations, experimental approaches using tomography, X-ray diffraction (XRD), and an analytical approach calculating the buckling distortion of a piston. The most essential geometrical features are thin walls situated between massive rings. An eigenvalue buckling analysis, a DMD process, and heat treatment simulation are presented. The eigenvalue buckling simulation shows that it is highly dependent on the mesh size. The computational effort of the DMD and heat treatment simulation was reduced through simplifications. Moreover, artificial imperfections were imposed in the heat treatment simulation, which moved the part into the buckling state inspired by the experiment. Although the numerical results of both simulations are successful, the eigenvalue and DMD simulation cannot be validated through tomography and XRD. This is because tomography is unable to measure small elastic strain fields, the simulated residual stresses were overestimated, and the part removal disturbed the residual stress equilibrium. Nevertheless, the heat treatment simulation can predict the distortion pattern caused by an inhomogeneous temperature field during ambient cooling in an oven. The massive piston skirt cools down and shrinks faster than the massive core. The reduced yield strength at elevated temperatures and critical buckling load leads to plastic deformation of the thin walls. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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21 pages, 10867 KiB  
Article
Mesoscale Simulation of Laser Powder Bed Fusion with an Increased Layer Thickness for AlSi10Mg Alloy
by Maria Bogdanova, Stanislav Chernyshikhin, Andrey Zakirov, Boris Zotov, Leonid Fedorenko, Sergei Belousov, Anastasia Perepelkina, Boris Korneev, Maria Lyange, Ivan Pelevin, Inna Iskandarova, Ella Dzidziguri, Boris Potapkin and Alexander Gromov
J. Manuf. Mater. Process. 2024, 8(1), 7; https://doi.org/10.3390/jmmp8010007 - 1 Jan 2024
Cited by 4 | Viewed by 3284
Abstract
Low performance is considered one of the main drawbacks of laser powder bed fusion (LPBF) technology. In the present work, the effect of the AlSi10Mg powder layer thickness on the laser melting process was investigated to improve the LPBF building rate. A high-fidelity [...] Read more.
Low performance is considered one of the main drawbacks of laser powder bed fusion (LPBF) technology. In the present work, the effect of the AlSi10Mg powder layer thickness on the laser melting process was investigated to improve the LPBF building rate. A high-fidelity simulation of the melt pool formation was performed for different thicknesses of the powder bed using the Kintech Simulation Software for Additive Manufacturing (KiSSAM, version cd8e01d) developed by the authors. The powder bed after the recoating operation was obtained by the discrete element method. The laser energy deposition on the powder particles and the substrate was simulated by ray tracing. For the validation of the model, an experimental analysis of single tracks was performed on two types of substrates. The first substrate was manufactured directly with LPBF technology, while the second was cast. The simulation was carried out for various combinations of process parameters, predominantly with a high energy input, which provided a sufficient remelting depth. The calculations revealed the unstable keyhole mode appearance associated with the low absorptivity of the aluminum alloy at a scanning speed of 300 mm/s for all levels of the laser power (325–375 W). The results allowed formulating the criteria for the lack of fusion emerging during LPBF with an increased layer thickness. This work is expected to provide a scientific basis for the analysis of the maximum layer thickness via simulation to increase the performance of the technology. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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20 pages, 12737 KiB  
Article
Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design
by Hui Huang, Yong Chae Lim, Yiyu Wang, Yuan Li and Zhili Feng
J. Manuf. Mater. Process. 2023, 7(6), 216; https://doi.org/10.3390/jmmp7060216 - 1 Dec 2023
Viewed by 2076
Abstract
Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A [...] Read more.
Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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22 pages, 36929 KiB  
Article
Towards a Simulation-Assisted Prediction of Residual Stress-Induced Failure during Powder Bed Fusion of Metals Using a Laser Beam: Suitable Fracture Mechanics Models and Calibration Methods
by Hannes Panzer, Daniel Wolf, Andreas Bachmann and Michael Friedrich Zaeh
J. Manuf. Mater. Process. 2023, 7(6), 208; https://doi.org/10.3390/jmmp7060208 - 27 Nov 2023
Cited by 2 | Viewed by 1955
Abstract
In recent years, Additive Manufacturing (AM) has emerged as a transformative technology, with the process of Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) gaining substantial attention for its precision and versatility in fabricating metal components. A major challenge in PBF-LB/M [...] Read more.
In recent years, Additive Manufacturing (AM) has emerged as a transformative technology, with the process of Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) gaining substantial attention for its precision and versatility in fabricating metal components. A major challenge in PBF-LB/M is the failure of the component or the support structure during the production process. In order to locate a possible residual stress-induced failure prior to the fabrication of the component, a suitable failure criterion has to be identified and implemented in process simulation software. In the work leading to this paper, failure criteria based on the Rice-Tracey (RT) and Johnson-Cook (JC) fracture models were identified as potential models to reach this goal. The models were calibrated for the nickel-based superalloy Inconel 718. For the calibration process, a conventional experimental, a combined experimental and simulative, and an AM-adapted approach were applied and compared. The latter was devised to account for the particular phenomena that occur during PBF-LB/M. It was found that the JC model was able to capture the calibration data points more precisely than the RT model due to its higher number of calibration parameters. Only the JC model calibrated by the experimental and AM-adapted approach showed an increased equivalent plastic failure strain at high triaxialities, predicting a higher cracking resistance. The presented results can be integrated into a simulation tool with which the potential fracture location as well as the cracking susceptibility during the manufacturing process of PBF-LB/M parts can be predicted. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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17 pages, 5774 KiB  
Article
Comprehensive Investigation of Hastelloy C-22 Powder Weld Overlay on SA 240 Type 316L Using Laser Beam Welding for Enhanced Performance
by Manish V. Mehta, Mrunalkumar D. Chaudhari, Rakesh Chaudhari, Sakshum Khanna and Jaykumar Vora
J. Manuf. Mater. Process. 2023, 7(6), 207; https://doi.org/10.3390/jmmp7060207 - 24 Nov 2023
Viewed by 2192
Abstract
This article presents a comprehensive study on the application of Hastelloy C-22 powder weld overlay on SA 240 Type 316L austenitic stainless steel using the laser beam welding process. This novel combination of materials and processes was investigated for the first time, focusing [...] Read more.
This article presents a comprehensive study on the application of Hastelloy C-22 powder weld overlay on SA 240 Type 316L austenitic stainless steel using the laser beam welding process. This novel combination of materials and processes was investigated for the first time, focusing on its potential utility for various industrial applications. Various testing techniques, including visual testing, hardness testing, bend testing, chemical composition analysis using optical spectroscopy, corrosion resistance assessment through the potentiodynamic polarization technique, and macro- and microstructural observation, were employed to evaluate the performance of the weld overlay. The research findings had several significant outcomes. Notably, precise control and minimal alloy mixing were achieved, as evidenced by the dilution at a remarkable height of 0.5 mm from the base metal. The laser welding process resulted in a minimal heat-affected zone and a fine columnar interdendritic microstructure, with average primary and secondary arm spacing values of 3.981 µm and 2.289 µm, respectively. Rigorous visual and bend testing confirmed the integrity of the sound welds in the overlay. Moreover, the high-quality finish of the weld overlay eliminated the need for extensive machining and finishing processes, resulting in cost reductions. This study also demonstrated primary and secondary inter-laminar spacing, leading to improved overall structural integrity. Additionally, the weld overlay exhibited excellent hardness characteristics. The current work contributes to the advancement of welding processes and provides practical solutions to enhance efficiency, cost-effectiveness, and structural performance in relevant industrial applications. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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Review

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18 pages, 5150 KiB  
Review
A Review on Fusion Welding of Dissimilar Ferritic/Austenitic Steels: Processing and Weld Zone Metallurgy
by Fabio Giudice, Severino Missori, Cristina Scolaro and Andrea Sili
J. Manuf. Mater. Process. 2024, 8(3), 96; https://doi.org/10.3390/jmmp8030096 - 4 May 2024
Viewed by 1845
Abstract
Dissimilar welds between ferritic and austenitic steels represent a good solution for exploiting the best performance of stainless steels at high and low temperatures and in aggressive environments, while minimizing costs. Therefore, they are widely used in nuclear and petrochemical plants; however, due [...] Read more.
Dissimilar welds between ferritic and austenitic steels represent a good solution for exploiting the best performance of stainless steels at high and low temperatures and in aggressive environments, while minimizing costs. Therefore, they are widely used in nuclear and petrochemical plants; however, due to the different properties of the steels involved, the welding process can be challenging. Fusion welding can be specifically applied to connect low-carbon or low-alloy steels with high-alloy steels, which have similar melting points. The welding of thick plates can be performed with an electric arc in multiple passes or in a single pass by means of laser beam equipment. Since the microstructure and, consequently, the mechanical properties of the weld are closely related to the composition, the choice of the filler metal and processing parameters, which in turn affect the dilution rate, plays a fundamental role. Numerous technical solutions have been proposed for welding dissimilar steels and much research has developed on welding metallurgy; therefore, this article is aimed at a review of the most recent scientific literature on issues relating to the fusion welding of ferritic/austenitic steels. Two specific sections are dedicated, respectively, to electric arc and laser beam welding; finally, metallurgical issues, related to dilution and thermal field are debated in the discussion section. Full article
(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)
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