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Advances in the Experimentation and Numerical Modeling of Material Joining Processes (Third Edition)

A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Materials Simulation and Design".

Deadline for manuscript submissions: 20 February 2026 | Viewed by 1170

Special Issue Editor


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Guest Editor
1. ISEP—School of Engineering, Polytechnic of Porto, R. Dr. António Bernardino de Almeida, 431, 4200-072 Porto, Portugal
2. INEGI—Institute of Science and Innovation in Mechanical and Industrial Engineering, Pólo FEUP, Rua Dr. Roberto Frias, 400, 4200-465 Porto, Portugal
Interests: composite materials; joining processes; automation
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Special Issue Information

Dear Colleagues,

Nowadays, structural design is facing major challenges in the associated joining processes, such as material selection, different thermal coefficients and melting points, multi-material joining, the joining of thin-walled structures, traditional process effectiveness for new materials, cost efficiency and ecological issues. To provide a strong, reliable and lightweight solution for a given application, the designer should either consider hybrid joining or choose from a large variety of available processes, such as welding, brazing, riveting, mechanical fastening, adhesive bonding, clinching, friction stir welding, laser welding, diffusion welding, amongst others. These joining processes have evolved towards optimization and cost reduction in the early design stages in terms of their implementation and industrialization, destructive and non-destructive testing, and either analytical or numerical modeling. Numerical modeling is particularly effective for simulating complex geometries, different load scenarios and materials with plasticity or anisotropy. The finite element method, together with fracture mechanics techniques, is a powerful and common approach employed in the scientific community but is less applied for the study of complex loads, such as high strain rates, fatigue or impact, and it is seldom used in the industry. To develop state-of-the-art techniques and disseminate the recent advances in all types of joining, either experimental or numerical, the Third Edition of this Special Issue intends to follow the successful path of the first two Editions and bring together a significant number of high-quality contributions to this field of research through innovative and original works, subsequently promoting their dissemination via open access publishing.

Dr. Raul D. S. G. Campilho
Guest Editor

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Keywords

  • joining process
  • welding
  • brazing
  • riveting
  • mechanical fastening
  • adhesive bonding
  • clinching
  • friction stir welding
  • laser welding
  • diffusion welding
  • hybrid joining
  • experimental testing
  • numerical modeling
  • strength prediction
  • failure path prediction
  • finite element method
  • fracture mechanics
  • static load
  • dynamic load
  • impact load
  • fatigue load
  • residual stress
  • mechanical properties
  • thin-walled structures

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Published Papers (1 paper)

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Research

21 pages, 7939 KB  
Article
Femtosecond Laser Single-Spot Welding of Sapphire/Invar Alloy
by Yuyang Chen, Yinzhi Fu, Xianshi Jia, Kai Li and Cong Wang
Materials 2025, 18(16), 3839; https://doi.org/10.3390/ma18163839 - 15 Aug 2025
Viewed by 546
Abstract
Ultrafast laser welding of glass/metal heterostructures has found extensive applications in sensors, medical devices, and optical systems. However, achieving high-stability, high-quality welds under non-optical contact conditions remains challenging due to severe internal damage within glass materials. This study addresses thermal management through synergistic [...] Read more.
Ultrafast laser welding of glass/metal heterostructures has found extensive applications in sensors, medical devices, and optical systems. However, achieving high-stability, high-quality welds under non-optical contact conditions remains challenging due to severe internal damage within glass materials. This study addresses thermal management through synergistic control of thermal accumulation effects and material ablation thresholds. Using the sapphire/Invar alloy system as a model for glass/metal welding, we investigated thermal accumulation effects during ultrafast laser ablation of Invar alloy through theoretical simulations. Under a repetition rate of 1 MHz, the femtosecond laser raised the lattice equilibrium temperature by 700 K within 10 microseconds, demonstrating that high repetition rate femtosecond lasers can induce effective heat accumulation in Invar alloy. Furthermore, ablation thresholds for both materials were determined across varying repetition rates via the D2 method, with corresponding threshold curves systematically constructed. Finally, based on the simulation and ablation threshold calculation results, laser parameters were selected for ultrafast laser single point welding of sapphire and Invar alloy. The experimental results demonstrate effective thermal effect mitigation, achieving a maximum shear strength of 63.37 MPa. Comparative analysis against traditional scan welding further validates the superiority of our approach in thermal management. This work provides foundational theoretical and methodological guidance for ultrafast laser welding of glass/metal heterostructures. Full article
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