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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 August 2023) | Viewed by 21339

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Special Issue Editors

Dr. Cosmin Codrean

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Guest Editor

Mechanical Faculty, Politehnica University of Timşoara, Bd. MihaiViteazu Nr.1, 300222 Timişoara, Romania
Interests: processing and characterization of advanced materials; amorphous and nanocrystalline alloys; metals and alloys; welding and brazing of advanced materials
Special Issues, Collections and Topics in MDPI journals

Dr. Anamaria Feier

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Guest Editor Assistant

Materials and Manufacturing Engineering Department, Politehnica University Timișoara, Bd. Mihai Viteazu Nr. 1, 300222 Timișoara, Romania
Interests: joining, manufacturing engineering; advanced welding and joining technologies; welding and joining of similar and dissimilar metals, additive manufacturing, metal-polymer hybrid joints, friction riveting, stress concentrations, fatigue

Dr. Carmen Opriș

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Guest Editor Assistant

Department of Materials and Manufacturing Engineering, Polytechnic University of Timisoara, 300222 Timişoara, Romania
Interests: advanced materials; material characterization; composite material; electron microscope; metal analysis alloys; biomedical alloys; materials engineering; materials testing; failure analysis

Special Issue Information

Dear Colleagues,

Recent developments in the engineering industry require new and advanced materials with special properties. Welding and joining these new materials present a major challenge to engineers and technicians involved in product design and manufacturing. Therefore, new materials research should be conducted hand in hand with work on weldability and joining capacity aspects, as well as the development of new welding techniques. At the same time, a better understanding of the relationship between the microstructure and mechanical properties of the brazed or welded joints will provide useful information to the materials development activities both in conventional and new materials areas.

The aim of this Special Issue is to provide a platform for researchers, engineers, academicians, as well as industrial professionals from all over the world to present their research results and development activities in the field of welding and joining of both advanced and conventional engineering materials.

In this Special Issue, research areas may include (but are not limited to) the following:

New joining technologies.
Quality of welded joints and welded structures.
Modeling and simulation of welding processes.
Specific problems in advanced materials joining.
Mechanical and structural characterization of advanced materials and joints.
Engineering applications of surface coatings.
Damage to metal and non-metal structures.

Dr. Cosmin Codrean
Guest Editor

Dr. Anamaria Feier
Dr. Carmen Opriș
Guest Editor Assistants

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. Materials 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 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

joining technologies
welding process
quality of welded joints
modeling and simulation
advanced materials
microstructure
mechanical properties
surface coatings

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Related Special Issue

Advances in Welding Process and Materials (2nd Edition) in Materials (7 articles)

Published Papers (12 papers)

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Research

16 pages, 3007 KiB

Open AccessArticle

Fabrication of Multi-Walled Structure through Parametric Study of Bead Geometries of GMAW-Based WAAM Process of SS309L

by Jay Vora, Rudram Pandey, Pratik Dodiya, Vivek Patel, Sakshum Khanna, Vatsal Vaghasia and Rakesh Chaudhari

Materials 2023, 16(14), 5147; https://doi.org/10.3390/ma16145147 - 21 Jul 2023

Cited by 10 | Viewed by 1494

Abstract

In the present study, an attempt is made to investigate and optimize the bead geometries of bead width (BW) and bead height (BH) of SS-309L using an SS316L substrate by employing a gas metal arc welding (GMAW)-based wire-arc additive manufacturing (WAAM) process. The Box–Behnken design approach was used to conduct the trials of single-layer depositions with input variables of travel speed (TS), voltage (V), and gas mixture ratio (GMR). The developed multi-variable regression models were tested for feasibility using ANOVA and residual plots. The data obtained indicated that V had the most significant impact on BW, followed by TS and GMR. For BH, TS had the most significant impact, followed by GMR and V. The results of single-response optimization using a passing vehicle search (PVS) algorithm showed a maximum BH of 9.48 mm and a minimum BW of 5.90 mm. To tackle the contradictory situation, a multi-objective PVS algorithm was employed, which produced non-dominated solutions. A multi-layered structure was successfully fabricated at the optimal parametric settings of TS at 20 mm/s, of voltage at 22 V, and of GMR at 3. For multi-layer structures, fusion among the layers was observed to be good, and they were found to be free from the disbonding of layers. This revealed the suitability of the PVS algorithm for generating suitable optimal WAAM variables. We consider the current work highly beneficial for users fabricating multi-layer structures. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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21 pages, 58939 KiB

Open AccessArticle

Study of the TIG Welding Process of Thin-Walled Components Made of 17-4 PH Steel in the Aspect of Weld Distortion Distribution

by Marek Mróz, Bartłomiej Kucel, Patryk Rąb and Sylwia Olszewska

Materials 2023, 16(13), 4854; https://doi.org/10.3390/ma16134854 - 6 Jul 2023

Cited by 1 | Viewed by 1435

Abstract

This article presents the results of a study on the distribution of weld distortion in thin-walled components made of 17-4 PH steel, resulting from TIG (Tungsten Inert Gas) welding. Both manual and automatic welding processes were examined. Physical simulation of the automated welding process was conducted on a custom-built welding fixture. Analysis of weld distortion in thin-walled components made of 17-4 PH steel was based on the results of measurements of transverse shrinkage and displacement angle values. These measurements were taken on thin-walled parts before and after the welding process using a coordinate measuring machine (CMM). To determine the effect of manual and automated welding processes on the microstructure of the welded joint area, metallographic tests and hardness measurements were performed. The microstructure was analyzed using a scanning electron microscope (SEM). An analysis of the chemical composition of selected welded joint zones was also conducted. These tests were performed using an optical emission spectrometer (OES). According to the results, the use of automated welding and special fixtures for manufacturing thin-walled aircraft engine components made of 17-4 PH steel reduces the propensity of these components for distortion due to the effects of the thermal cycle of the welding process. This conclusion is supported by the results of the observation of the microstructure and analysis of the chemical composition of the various zones of the welded joint area. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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18 pages, 7816 KiB

Open AccessArticle

Effects of Different Pre-Heating Welding Methods on the Temperature Field, Residual Stress and Deformation of a Q345C Steel Butt-Welded Joint

by Jie Yuan, Hongchao Ji, Yingzhuo Zhong, Guofa Cui, Linglong Xu and Xiuli Wang

Materials 2023, 16(13), 4782; https://doi.org/10.3390/ma16134782 - 2 Jul 2023

Cited by 4 | Viewed by 1726

Abstract

Heavy plate welding has been widely used in the construction of large projects and structures, in which the residual stress and deformation caused by the welding process are the key problems to address to reduce the stability and safety of the whole structure. Strengthening before welding is an important method to reduce the temperature gradient, control the residual stress and reduce the deformation of welds. Based on the ABAQUS software, the thermal elastoplastic finite element method (FEM) was used to simulate the welding thermal cycle, residual stress and deformation of low-alloy, high-strength steel joints. Based on the finite element simulation, the influences of flame heating and ceramic heating on the temperature field, residual stress distribution and deformation of a Q345C steel butt-welded joint were studied. The results showed that the thermal cycle of the ceramic sheet before welding had little influence on the whole weldment, but had great influence on the residual stress of the weldment. The results show that the maximum temperature and residual stress of the welded parts are obviously weakened under the heating of ceramic pieces, and the residual stress of the selected feature points is reduced by 5.88%, and the maximum temperature of the thermal cycle curve is reduced by 22.67%. At the same time, it was concluded that the weld shapes of the two were basically the same, but the weld seams heated by ceramic pieces had a better weld quality and microstructures through comparing the macro- and micro-structures between the welded parts heated by ceramic pieces and the simulated weld. Heating before welding, therefore, is an effective method to obtain a high weld quality with less residual stress and deformation. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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14 pages, 5701 KiB

Open AccessArticle

Effect of Shielding Gas Arc Welding Process on Cavitation Resistance of Welded Joints of AlMg4.5Mn Alloy

by Marina Dojčinović, Radica Prokić Cvetković, Aleksandar Sedmak, Olivera Popović, Ivana Cvetković and Dorin Radu

Materials 2023, 16(13), 4781; https://doi.org/10.3390/ma16134781 - 2 Jul 2023

Viewed by 1147

Abstract

The effect of the shielding gas arc welding process on the cavitation resistance of the three-component aluminum alloy AlMg4.5Mn and its welded joints was investigated. Welding was performed using the GTAW and GMAW processes in a shielded atmosphere of pure argon. After the welding, metallographic tests were performed, and the hardness distribution in the welded joints was determined. The ultrasonic vibration method was used to evaluate the base metal’s and weld metal’s resistance to cavitation. The change in mass was monitored to determine the cavitation rates. The morphology of the surface damage of the base metal and weld metal due to cavitation was monitored using scanning electron microscopy to explain the effect of the shielding gas arc welding process on their resistance to cavitation. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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11 pages, 7162 KiB

Open AccessArticle

Effect of Mechanical Stirring on High-Speed GMAW Hump Bead

by Jun Xiao, Xiaolei Wang, Shengnan Gai, Shujun Chen and Wenhao Huang

Materials 2023, 16(12), 4493; https://doi.org/10.3390/ma16124493 - 20 Jun 2023

Cited by 2 | Viewed by 1187

Abstract

High-speed GMAW tends to be accompanied by periodic humping defects, thereby reducing the weld bead quality. A new method was proposed to actively control the weld pool flow for eliminating humping defects. A high-melting point solid pin was designed and inserted into the weld pool to stir the liquid metal during the welding process. The characteristics of the backward molten metal flow were extracted and compared by a high-speed camera. Combined with particle tracing technology, the momentum of the backward metal flow was calculated and analyzed, and the mechanism of hump suppression in high speed GMAW was further revealed. The stirring pin interacted with the liquid molten pool, resulting in a vortex zone behind the stirring pin, which significantly reduced the momentum of the backward molten metal flow, and thus it inhibited the formation of humping beads. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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12 pages, 3536 KiB

Open AccessArticle

Fabrication of Flexible Supercapacitor Electrode Materials by Chemical Oxidation of Iron-Based Amorphous Ribbons

by Mircea Nicolaescu, Melinda Vajda, Carmen Lazau, Corina Orha, Cornelia Bandas, Viorel-Aurel Serban and Cosmin Codrean

Materials 2023, 16(7), 2820; https://doi.org/10.3390/ma16072820 - 1 Apr 2023

Cited by 5 | Viewed by 1940

Abstract

A flexible electrode constructed from Fe-based amorphous ribbons decorated with nanostructured iron oxides, representing the novelty of this research, was successfully achieved in one-step via a chemical oxidation method, using a low concentration of NaOH solution. The growth of metal oxides on a conductive substrate, which forms some metal/oxide structure, has been demonstrated to be an efficient method for increasing the charge transfer efficiency. Through the control and variation of synthetic parameters, different structures and morphologies of iron oxide were obtained, including hexagonal structures with a hollow ball shape and rhombohedral structures with rhombus-like shapes. Structural and morphological characterization methods such as X-ray diffraction and SEM morphology were used on the as-synthesized composite materials. The supercapacitor properties of the as-developed amorphous ribbons decorated with Fe₂O₃ nanoparticles were investigated by cyclic voltammetry, galvanostatic charge discharge, and electrochemical impedance spectroscopy. The flexible supercapacitor negative electrode demonstrates a specific capacitance of 5.96 F g⁻¹ for the 0.2 M NaOH treated sample and 8.94 Fg⁻¹ for the 0.4 M NaOH treated sample. The 0.2 M treated negative electrodes deliver 0.48 Wh/kg at a power density of 20.11 W/kg, and the 0.4 M treated electrode delivers 0.61 Wh/kg at a power density of 20.85 W/kg. The above results show that these flexible electrodes are adequate for integration in supercapacitor devices, for example, as negative electrodes. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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18 pages, 4091 KiB

Open AccessArticle

Optimisation of the Heterogeneous Joining Process of AlMg3 and X2CrNiMo17-12-2 Alloy by FSW Method

by Anamaria Feier, Ioan Both and Edward Petzek

Materials 2023, 16(7), 2750; https://doi.org/10.3390/ma16072750 - 29 Mar 2023

Cited by 1 | Viewed by 2200

Abstract

This paper presents experimental investigations on the solid-state joint of 3 mm sheets of AlMg3 alloy with X2CrNiMo17-12-2 stainless steel. The study presents a dissimilar joint that was made in a solid state using a modified milling cutter. The study highlights the possibility of using this type of joint in a naval field. The paper presents all the steps of the joining process, from the technological parameters to the examination and numerical validation of the obtained specimens. A numerical model was defined in Abaqus, considering a Static analysis, and the results demonstrated a good similarity with a small discrepancy observed in the elastic range of the specimen behaviour. In the conclusions, this study will provide some recommendations for the optimisation of this joint and proposals for future studies; the idea for this study started from the dissimilar joints used in the naval field. The article also briefly presents some dissimilar joints made on the same milling machine and in the same laboratory. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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17 pages, 9851 KiB

Open AccessArticle

Cavitation Erosion Characteristics of the EN AW-6082 Aluminum Alloy by TIG Surface Remelting

by Ion Mitelea, Ilare Bordeașu, Florin Frant, Ion-Dragoș Uțu, Corneliu Marius Crăciunescu and Cristian Ghera

Materials 2023, 16(7), 2563; https://doi.org/10.3390/ma16072563 - 23 Mar 2023

Cited by 4 | Viewed by 1386

Abstract

Components made of aluminum alloys operating under cavitation erosion conditions have low performance and therefore a reduced lifetime. The degradation of these components is a consequence of the repetitive implosion of cavitation bubbles adjacent to the solid surface. In this paper, the effect of the rapid re-melting and solidification modification of the surface microstructure of parts of an Al-based alloy strengthened by artificial ageing on the reduction of material loss through cavitation erosion was investigated. The heat source used was the electric arc generated between a tungsten electrode and the workpiece (i.e., TIG). Local surface melting was performed at different values of linear energy (El = 6600–15840 J/cm), varying the current between 100 A and 200 A, at a constant voltage of 10 V. The obtained results showed an increase in the surface microhardness at values of 129–137 HV0.05 and a decrease in the erosion rate from 0.50 µm/min, characteristic of the artificial ageing heat treatment, to 0.10–0.32 µm/min, specific to TIG re-melted layers. For the study of the cavitational erosion mechanism, investigations were carried out by optical microscopy and scanning electron microscopy. The results showed that the improvement of the cavitational erosion resistance by surface melting was a consequence of the increase in microstructural homogeneity and grains refinement. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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16 pages, 5071 KiB

Open AccessArticle

Analysis of Kerf Quality Characteristics of Kevlar Fiber-Reinforced Polymers Cut by Abrasive Water Jet

by Dinu-Valentin Gubencu, Carmen Opriș and Adelina-Alina Han

Materials 2023, 16(6), 2182; https://doi.org/10.3390/ma16062182 - 8 Mar 2023

Cited by 5 | Viewed by 1653

Abstract

Abrasive water jet machining has become an indispensable process for cutting Kevlar fiber-reinforced polymers used in applications such as ballistics protection, race cars, and protective gloves. The complex and diffuse action of a large number of input parameters leads to the need to evaluate the quality characteristics of the technological transformation as a result of the deployment of experimental studies adapted to the specific processing conditions. Thus, the paper focuses on identifying the influence of different factors and modeling their action on the characteristics that define the quality of the cut parts, such as the kerf taper angle and the Ra roughness parameter, by applying statistical methods of design and analysis of experiments. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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13 pages, 6716 KiB

Open AccessArticle

Microstructure and Cavitation Damage Characteristics of GX40CrNiSi25-20 Cast Stainless Steel by TIG Surface Remelting

by Ion Mitelea, Ilare Bordeaşu, Daniela Cosma (Alexa), Ion-Dragoș Uțu and Corneliu Marius Crăciunescu

Materials 2023, 16(4), 1423; https://doi.org/10.3390/ma16041423 - 8 Feb 2023

Cited by 5 | Viewed by 1657

Abstract

Cavitation erosion degrades the surface of engineering components when the material is exposed to turbulent fluid flows. Under conditions of local pressure fluctuations, a nucleation of gas or vapor bubbles occurs. If the pressure suddenly drops below the vapor pressure, these bubbles collapse violently when subjected to higher pressure. This collapse is accompanied by the sudden flow of the liquid, which is manifested by stress pulses capable of causing plastic deformations on solid surfaces. Repeating these stress conditions can cause material removal and ultimately failure of the component itself. The present study aims to reduce the negative impact of this phenomenon on the mechanical systems components, using the TIG local surface remelting technique. Cavitation erosion tests were performed in accordance with the ASTM G32-2016 standard on samples taken from a cast high-alloy stainless steel. The alloy response for each melting current value was investigated by measuring mass loss as a function of cavitation attack time and by analyzing the damaged surfaces using optical and scanning electron microscopes. It was highlighted that the TIG remelted layers provide an increase in cavitation erosion resistance of 5–6 times as a consequence of the fine graining and microstructure induced by the technique applied. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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14 pages, 11050 KiB

Open AccessArticle

Characteristics of Hydroxyapatite-Modified Coatings Based on TiO₂ Obtained by Plasma Electrolytic Oxidation and Electrophoretic Deposition

by Roxana Muntean, Mihai Brîndușoiu, Dragoș Buzdugan, Nicoleta Sorina Nemeș, Andrea Kellenberger and Ion Dragoș Uțu

Materials 2023, 16(4), 1410; https://doi.org/10.3390/ma16041410 - 8 Feb 2023

Cited by 8 | Viewed by 1793

Abstract

In order to modify the surface of light metals and alloys, plasma electrolytic oxidation (PEO) is a useful electrochemical technique. During the oxidation process, by applying a positive high voltage greater than the dielectric breakdown value of the oxide layer, the formation of a ceramic film onto the substrate material is enabled. The resulting surface presents hardness, chemical stability, biocompatibility, and increased corrosion wear resistance. The current study aims to investigate the corrosion resistance and tribological properties of PEO-modified coatings on titanium substrates produced by applying either direct or pulsed current in a silicate-alkaline electrolyte. In this way, a uniform TiO₂ layer is formed, and subsequently, electrophoretic deposition of hydroxyapatite particles (HAP) is performed. The morpho-structural characteristics and chemical composition of the resulting coatings are investigated using scanning electron microscopy combined with energy dispersive spectroscopy analysis and X-ray diffraction. Dry sliding wear testing of the TiO₂ and HAP-modified TiO₂ coatings were carried out using a ball-on-disc configuration, while the corrosion resistance was electrochemically evaluated at 37 °C in a Ringer’s solution. The corrosion rates of the investigated samples decreased significantly, up to two orders of magnitude, when the PEO treatment was applied, while the wear rate was 50% lower compared to the untreated titanium substrate. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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22 pages, 2845 KiB

Open AccessArticle

Grey Relational Analysis and Grey Prediction Model (1, 6) Approach for Analyzing the Electrode Distance and Mechanical Properties of Tandem MIG Welding Distortion

by Hsing-Chung Chen, Andika Wisnujati, Mudjijana, Agung Mulyo Widodo and Chi-Wen Lung

Materials 2023, 16(4), 1390; https://doi.org/10.3390/ma16041390 - 7 Feb 2023

Cited by 3 | Viewed by 1774

Abstract

The tandem metal inert gas (MIG) process uses two wires that are continuously fed through a special welding torch and disbursed to form a single molten pool. Within the contact tip of the modern approach, the wires are electrically insulated from one another. This study identified the effect of welding electrode spacing on the distortion of AA5052 aluminum plates and different mechanical properties including hardness and thermal cycle using grey relational analysis. Plate distortion was subsequently predicted using the grey prediction model GM (1, 6). This research used a pair of 400 mm × 75 mm × 5 mm of AA5052 plates and electrode distances of 18, 27, and 36 mm. The welding current, voltage, welding speed, and argon flow rate were 130 A, 23 V, 7 mm/s, and 17 L/min, respectively. The temperature was measured using a type-K thermocouple at 10, 20, 30, and 40 mm from the center of the weld bead. The smallest distortion at an electrode distance of 27 mm was 1.4 mm. At an electrode distance of 27 mm, the plate may reach a proper peak temperature where the amount of heat input and dissipation rate are similar to those for electrode distances of 18 mm and 36 mm. The highest relative VHN of 57 was found in the BM, while the lowest, 46, was found in the WM, showing good agreement with their respective grain sizes. Six parameters were designed using grey relational analysis (GRA) and subsequently employed in the grey prediction model GM (1, 6). Process evaluation results show that predictions for welding distortions are consistent with actual results, thus, the GM (1, 6) model can be used as a predictive model for welding distortions of 5052 aluminum plates. Full article

(This article belongs to the Special Issue Advances in Welding Process and Materials)

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