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Metals
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High-Productivity Welding of Metals and Alloys
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High-Productivity Welding of Metals and Alloys

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Welding and Joining".

Deadline for manuscript submissions: closed (31 December 2021) | Viewed by 18259

Special Issue Editor

Prof. Dr. Elena Scutelnicu

E-Mail Website
Guest Editor
Faculty of Engineering, “Dunarea de Jos” University of Galati, Strada Domnească 47, Galați, Romania
Interests: manufacturing engineering; advanced welding technologies; welding of similar and dissimilar metals; characterisation of welded joints; modelling and simulation of welding
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Welding is one of the most common joining processes employed in the industry of metal and alloy structures. Nowadays, to be able to compete in the world of advanced joining technologies of materials and, further, to achieve competitive products, the key success factors are quality, productivity, and cost. Consequently, manufactures of structures are continuously looking for advanced technical solutions to be applied for increasing process productivity and for reducing production cost. Moreover, quality in the industry of welded structures is essential, and, therefore, the main stakeholders involved in the design and fabrication have to take into consideration the multi-criteria optimization, in terms of the process parameters and  joint performances, as well as productivity and cost.

To maintain competitiveness in the industry of shipbuilding, aerospace, automotive, oil and gas transport, and other industrial sectors, innovative welding technologies, such as robotised welding, hybrid welding, and multi-arc and multi-wire welding, need to be developed and applied in fabrication. However, to simultaneously achieve safety in service and competitiveness in the market, an optimum balance between the good-quality requirement and the demand for high-productivity processes and low fabrication costs should be kept under control.   

Researchers worldwide are invited to contribute to this Special Issue, which aims to disseminate, on a large scale, the recent developments in high-productivity welding technologies, the behaviour of materials subjected to welding, the characterisation of welded joints, numerical modelling of fusion welding, and advanced industrial applications. Experimental studies and simulations covering the intercorrelation of process parameters, microstructure, and properties, such as strength, toughness, hardness, weldability, and corrosion resistance, are encouraged and welcomed.

Prof. Dr. Elena Scutelnicu
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. Metals 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 2600 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

  • Multi-arc welding
  • Multi-wire welding
  • Hybrid welding
  • Robotized welding
  • Welding of thick materials
  • Welding of high-strength steels
  • Characterisation of welded joints
  • Numerical analysis

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Published Papers (5 papers)

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Research

15 pages, 4157 KiB  
Article
Effect of Diffusion on Dissimilar Welded Joint between Al0.8CoCrFeNi High-Entropy Alloy and S235JR Structural Steel
by Ionelia Voiculescu, Victor Geanta, Elena Violeta Stefanescu, George Simion and Elena Scutelnicu
Metals 2022, 12(4), 548; https://doi.org/10.3390/met12040548 - 24 Mar 2022
Cited by 9 | Viewed by 3196
Abstract
This research focused on the investigation of the metallurgical behavior of the Al0.8CoCrFeNi high-entropy alloy and S235JR structural steel, welded with (Ni, Fe)-rich filler metal, by the Gas Tungsten Arc Welding (GTAW) method. The electric arc and the welding pool were [...] Read more.
This research focused on the investigation of the metallurgical behavior of the Al0.8CoCrFeNi high-entropy alloy and S235JR structural steel, welded with (Ni, Fe)-rich filler metal, by the Gas Tungsten Arc Welding (GTAW) method. The electric arc and the welding pool were protected against the contamination with gases from the environment, by employing high-purity Ar 4.8 inert gas that plays an important role in reducing the oxidation effects and the development of cracks in the weld and the adjacent areas. The microstructure and microhardness analysis did not reveal the existence of fragile phases, cracks, inadequate penetration, or other imperfections, showing an appropriate adhesion between the deposited metal and the substrates. At the interface between the Ni-rich weld metal and the high-entropy alloy, a higher hardness (448 HV0.2) than in the base material (358 HV0.2) was measured. Energy-dispersive X-ray analysis (EDS), performed at the interface between the weld metal and the base materials, did not show significant modifications of Co, Fe, and Cr percentages. However, during the investigation, significant variations in Al and Ni concentrations were observed, caused by the fast diffusion of chemical elements, and the development of hard (Ni, Al)-rich compounds. In some areas of the deposited metal, located at a distance of about 10 µm from the interface, the percentages of Ni and Al were higher than in the high-entropy alloy base material, being around 41% by weight Ni and over 13% by weight Al, while the concentrations of the Co, Cr, and Fe elements proportionally decreased (i.e., approximately 14% by weight Co, 12% by weight Cr, and 17% by weight Fe). The development of Ni3Al and NiAl compounds was also noticed, whose formation was determined by the local chemical concentration and the temperature reached in the vicinity of the diffusion zone. The XRD analysis showed a group of X-ray peaks in the Al0.8CrFeCoNi alloy that corresponded to both α-type—BCC and FCC phases. The crystallite size of the high-entropy alloy investigated was found to be 22.05 nm. Despite the diffusion phenomenon, if filler materials and process parameters are appropriately selected, quality joints of high-entropy alloys and structural steels can be carried out under good welding conditions. Full article
(This article belongs to the Special Issue High-Productivity Welding of Metals and Alloys)
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24 pages, 9338 KiB  
Article
Investigating Nanoindentation Creep Behavior of Pulsed-TIG Welded Inconel 718 and Commercially Pure Titanium Using a Vanadium Interlayer
by Tauheed Shehbaz, Fahd Nawaz Khan, Massab Junaid and Julfikar Haider
Metals 2021, 11(9), 1492; https://doi.org/10.3390/met11091492 - 20 Sep 2021
Cited by 7 | Viewed by 2801
Abstract
In a dissimilar welded joint between Ni base alloys and titanium, creep failure is a potential concern as it could threaten to undermine the integrity of the joint. In this research, the mechanical heterogeneity of a Pulsed TIG welded joint between commercially pure [...] Read more.
In a dissimilar welded joint between Ni base alloys and titanium, creep failure is a potential concern as it could threaten to undermine the integrity of the joint. In this research, the mechanical heterogeneity of a Pulsed TIG welded joint between commercially pure titanium (CpTi) and Inconel 718 (IN718) with a vanadium (V) interlayer was studied through a nanoindentation technique with respect to hardness, elastic modulus, and ambient temperature creep deformation across all regions (fusion zones and interfaces, mainly composed of a dendritic morphology). According to the experimental results, a nanohardness of approximately 10 GPa was observed at the V/IN718 interface, which was almost 70% higher than that at the V/CpTi interface. This happened due to the formation of intermetallic compounds (IMCs) (e.g., Ti2Ni, NiV3, NiTi) and a (Ti, V) solid solution at the V/IN718 and V/CpTi interfaces, respectively. In addition, nanohardness at the V/IN718 interface was inhomogeneous as compared to that at the V/CpTi interface. Creep deformation behavior at the IN718 side was relatively higher than that at different regions on the CpTi side. The decreased plastic deformation or creep effect of the IMCs could be attributed to their higher hardness value. Compared to the base metals (CpTi and IN718), the IMCs exhibited a strain hardening effect. The calculated values of the creep stress exponent were found in the range of 1.51–3.52 and 2.52–4.15 in the V/CpTi and V/IN718 interfaces, respectively. Furthermore, the results indicated that the creep mechanism could have been due to diffusional creep and dislocation climb. Full article
(This article belongs to the Special Issue High-Productivity Welding of Metals and Alloys)
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13 pages, 6792 KiB  
Article
Double-Pulse Triple-Wire MIG Welding of 6082-T6 Aluminum Alloy: Process Characteristics and Joint Performances
by Ke Yang, Fei Wang, Hongbing Liu, Peng Wang, Chuanguang Luo, Zhishui Yu, Lijun Yang and Huan Li
Metals 2021, 11(9), 1388; https://doi.org/10.3390/met11091388 - 31 Aug 2021
Cited by 13 | Viewed by 4146
Abstract
High-efficiency and high-quality welding has always been the focus of welding research. This article proposes a novel double-pulse, triple-wire MIG welding process for the welding of 6082-T6 aluminum alloy. The process characteristics of welding arc and droplet transfer were studied, and the performances [...] Read more.
High-efficiency and high-quality welding has always been the focus of welding research. This article proposes a novel double-pulse, triple-wire MIG welding process for the welding of 6082-T6 aluminum alloy. The process characteristics of welding arc and droplet transfer were studied, and the performances of weld formation, morphology, hardness, and tensile strength were tested for the 1 Hz, 3 Hz, and 5 Hz double-pulse welding and normal-pulse welding. It was found that in the welding process, the pulsed arc steadily alternated among three welding wires without arc interruption, and the arc length changed periodically with the double-pulse frequency. The droplets transferred with a stable one-pulse-one-drop mode. Besides, a proper double-pulse frequency, e.g., 3 Hz in this case, was conducive to forming good welds with regular fish-scale patterns and no pores. The tensile strength of the joint could reach 64% of the base material’s tensile strength, and its fracture belonged to plastic fracture, which occurred in the HAZ. This new welding method will have great potential in aluminum alloy welding. Full article
(This article belongs to the Special Issue High-Productivity Welding of Metals and Alloys)
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16 pages, 2484 KiB  
Article
Optimization of Activated Tungsten Inert Gas Welding Process Parameters Using Heat Transfer Search Algorithm: With Experimental Validation Using Case Studies
by Jay Vora, Vivek K. Patel, Seshasai Srinivasan, Rakesh Chaudhari, Danil Yurievich Pimenov, Khaled Giasin and Shubham Sharma
Metals 2021, 11(6), 981; https://doi.org/10.3390/met11060981 - 19 Jun 2021
Cited by 37 | Viewed by 3327
Abstract
The Activated Tungsten Inert Gas welding (A-TIG) technique is characterized by its capability to impart enhanced penetration in single pass welding. Weld bead shape achieved by A-TIG welding has a major part in deciding the final quality of the weld. Various machining variables [...] Read more.
The Activated Tungsten Inert Gas welding (A-TIG) technique is characterized by its capability to impart enhanced penetration in single pass welding. Weld bead shape achieved by A-TIG welding has a major part in deciding the final quality of the weld. Various machining variables influence the weld bead shape and hence an optimum combination of machining variables is of utmost importance. The current study has reported the optimization of machining variables of A-TIG welding technique by integrating Response Surface Methodology (RSM) with an innovative Heat Transfer Search (HTS) optimization algorithm, particularly for attaining full penetration in 6 mm thick carbon steels. Welding current, length of the arc and torch travel speed were selected as input process parameters, whereas penetration depth, depth-to-width ratio, heat input and width of the heat-affected zone were considered as output variables for the investigations. Using the experimental data, statistical models were generated for the response characteristics. Four different case studies, simulating the real-time fabrication problem, were considered and the optimization was carried out using HTS. Validation tests were also carried out for these case studies and 3D surface plots were generated to confirm the effectiveness of the HTS algorithm. It was found that the HTS algorithm effectively optimized the process parameters and negligible errors were observed when predicted and experimental values compared. HTS algorithm is a parameter-less optimization technique and hence it is easy to implement with higher effectiveness. Full article
(This article belongs to the Special Issue High-Productivity Welding of Metals and Alloys)
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13 pages, 4010 KiB  
Article
The Effect of Wire Feeding Speed on Solidification Cracking of CMT Welding for Al-Si Alloys
by Lei Huang, Xizhang Chen, Sergey Konovalov, Arshad Noor Siddiquee, Gang Lu and Xiaoming Pan
Metals 2021, 11(2), 267; https://doi.org/10.3390/met11020267 - 4 Feb 2021
Cited by 11 | Viewed by 3277
Abstract
In this work, a welding solidification crack sensitivity test platform was established to study the effect of wire feeding speed (WFS) on solidification crack sensitivity during cold metal transfer (CMT) welding for AA6061 aluminum alloy. The test results show that as the WFS [...] Read more.
In this work, a welding solidification crack sensitivity test platform was established to study the effect of wire feeding speed (WFS) on solidification crack sensitivity during cold metal transfer (CMT) welding for AA6061 aluminum alloy. The test results show that as the WFS increased from 4 m/min to 5.5 m/min, the sensitivity of the solidification cracks also increased. With a further increase in the value of the WFS, the crack sensitivity decreased and eventually ceased to exist. A new perspective of the microstructure and crack propagation mechanics model was applied to understand the effect of WFS on solidification cracks. With the use of scanning electron microscopy (SEM) and a high-speed camera, it was found that as the WFS increased from 4 m/min to 5.5 m/min, the microstructure of the grain size changed from bigger to smaller, and the stability of the crystal microstructure was reduced. The crack propagation mechanics model was changed, which promotes crack propagation, increasing by 233%. When the WFS continued to increase beyond 5.5 m/min, the size of the crystal structure changed from small to big, the stability of the crystal microstructure was increased, the crack generation was suppressed, and the cracking rate was significantly reduced. Full article
(This article belongs to the Special Issue High-Productivity Welding of Metals and Alloys)
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