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Advances in Solid-State Welding Processes
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Advances in Solid-State Welding Processes

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

Deadline for manuscript submissions: 20 July 2025 | Viewed by 4225

Special Issue Editors

Prof. Dr. Peng Li

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
Interests: solid-state welding process; friction-based welding processes; diffusion bonding; brazing; welding of dissimilar metals
Dr. Feng Jin

E-Mail Website
Guest Editor
School of Materials Science and Engineering, Jiangsu University, Zhenjiang, China
Interests: solid-state welding process; friction-based welding processes; diffusion bonding; fatigue of friction welded joint

Special Issue Information

Dear Colleagues,

Solid-state welding is a relatively new welding technology. Compared with traditional fusion welding, it can avoid many of the defects associated with fusion welding, such as pores and solidification cracks. Furthermore, solid-state welding produces joints with high performance.  Therefore, it is widely used in aerospace, automobile manufacturing, and other fields. Research on solid-state welding is of great significance for improving welding quality, reducing production costs, and improving environmental pollution.

At present, solid-state welding technology has made certain progress, including rotary friction welding, friction stir welding, linear friction welding, diffusion bonding, resistance welding, and other methods. These methods have achieved certain results in practical applications, but there are still some difficulties that need to be solved in other aspects.

Current solid-state welding technology is suitable for high-strength and reliable welding of a variety of materials such as steel, aluminum alloys, titanium alloys, and other materials. However, further research and development of suitable solid-state welding methods are needed. Since the solid-state welding process has strict requirements on parameters such as temperature, pressure, and friction speed, the welding process needs to be precisely controlled to improve the welding quality and stability. At present, the detection of solid-state welded joints mainly relies on microstructure observation and mechanical property testing. However, these methods are subjective and uncertain, and more accurate and reliable welded joint quality inspection technologies need to be researched and developed.

In summary, the research on solid-state welding technology is of great significance. It is my great pleasure to invite everyone to submit a manuscript for this Special Issue. Full papers, communications, or reviews on solid-state welding are welcome.

Prof. Dr. Peng Li
Dr. Feng Jin
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. 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

  • solid-state welding process
  • friction-based welding processes
  • diffusion bonding
  • resistance welding
  • rotary friction welding
  • friction stir welding
  • linear friction welding
  • welding of dissimilar metals
  • microstructure evolution and joint performance

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Published Papers (3 papers)

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Research

14 pages, 15598 KiB  
Article
Properties of Wedge Wire Bonded Connection Between a Composite Copper Core Aluminum Shell Wire and an 18650 Cylindrical Lithium-Ion Battery Cell
by Krzysztof Bieliszczuk and Tomasz M. Chmielewski
Materials 2024, 17(21), 5237; https://doi.org/10.3390/ma17215237 - 28 Oct 2024
Cited by 1 | Viewed by 941
Abstract
Wedge wire bonding is a solid-state joining process that uses ultrasonic vibrations in combination with compression of the materials to establish an electrical connection. In the battery industry, this process is used to interconnect cylindrical battery cells due to its ease of implementation, [...] Read more.
Wedge wire bonding is a solid-state joining process that uses ultrasonic vibrations in combination with compression of the materials to establish an electrical connection. In the battery industry, this process is used to interconnect cylindrical battery cells due to its ease of implementation, high flexibility and ease of automation. Wire materials typically used in battery pack manufacturing are pure or alloyed aluminum and copper. While copper wires possess better electrical properties, the force used in the bonding process can lead to cell isolator damage and cell thermal runaway. This is an unacceptable result of the bonding process and has led to the development of new types of composite wires containing a copper core embedded in an aluminum shell. This material has the advantage of high copper electrical and thermal conductivity combined with less aggressive bonding parameters of the aluminum wire. The aim of this study was to establish a process window for the wedge wire bonding of 400 µm composite copper–aluminum Heraeus CucorAl Plus wire on the surface of a BAK 18650 battery cell. This study was conducted using a Hesse Bondjet BJ985 CNC wire bonder fitted with an RBK03 bond head designed for the bonding of copper wires. The methods used in this study included light and scanning electron microscopy of bond and battery cell cross-sections, shear testing on the XYZtec Sigma bond tester system, and energy dispersive spectroscopy. The results were compared with a previous study conducted using a wire of the same diameter and made out of high-purity aluminum. Full article
(This article belongs to the Special Issue Advances in Solid-State Welding Processes)
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18 pages, 5957 KiB  
Article
Temperature Effect on Deformation Mechanisms and Mechanical Properties of Welded High-Mn Steels for Cryogenic Applications
by Minha Park, Gang Ho Lee, Geon-Woo Park, Gwangjoo Jang, Hyoung-Chan Kim, Sanghoon Noh, Jong Bae Jeon, Byoungkoo Kim and Byung Jun Kim
Materials 2024, 17(16), 4159; https://doi.org/10.3390/ma17164159 - 22 Aug 2024
Viewed by 1169
Abstract
High-manganese steel (high-Mn) is valuable for its excellent mechanical properties in cryogenic environments, making it essential to understand its deformation behavior at extremely low temperatures. The deformation behavior of high-Mn steels at extremely low temperatures depends on the stacking fault energy (SFE) that [...] Read more.
High-manganese steel (high-Mn) is valuable for its excellent mechanical properties in cryogenic environments, making it essential to understand its deformation behavior at extremely low temperatures. The deformation behavior of high-Mn steels at extremely low temperatures depends on the stacking fault energy (SFE) that can lead to the formation of deformation twins or transform to ε-martensite or α′-martensite as the temperature decreases. In this study, submerged arc welding (SAW) was applied to fabricate thick pipes for cryogenic industry applications, but it may cause problems such as an uneven distribution of manganese (Mn) and a large weldment. To address these issues, post-weld heat treatment (PWHT) is performed to achieve a homogeneous microstructure, enhance mechanical properties, and reduce residual stress. It was found that the difference in Mn content between the dendrite and interdendritic regions was reduced after PWHT, and the SFE was calculated. At cryogenic temperatures, the SFE decreased below 20 mJ/m2, indicating the martensitic transformation region. Furthermore, an examination of the deformation behavior of welded high-Mn steels was conducted. This study revealed that the tensile deformed, as-welded specimens exhibited ε and α′-martensite transformations at cryogenic temperatures. However, the heat-treated specimens did not undergo α′-martensite transformations. Moreover, regardless of whether the specimens were subjected to Charpy impact deformation before or after heat treatment, ε and α′-martensite transformations did not occur. Full article
(This article belongs to the Special Issue Advances in Solid-State Welding Processes)
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15 pages, 14238 KiB  
Article
Quasi-In Situ Observation of the Microstructural Response during Fatigue Crack Growth of Friction Stir Welded AA2024-T4 Joint
by Jun Yang, Xianmin Chen, Huaxia Zhao, Jihong Dong and Feng Jin
Materials 2024, 17(9), 2106; https://doi.org/10.3390/ma17092106 - 29 Apr 2024
Viewed by 1347
Abstract
The reliability of friction stir welded joints is a critical concern, particularly given their potential applications in the aerospace manufacturing industry. This study offers a quasi-in situ observation of the microstructural response during fatigue crack growth (FCG) of a friction stir welded AA2024-T4 [...] Read more.
The reliability of friction stir welded joints is a critical concern, particularly given their potential applications in the aerospace manufacturing industry. This study offers a quasi-in situ observation of the microstructural response during fatigue crack growth (FCG) of a friction stir welded AA2024-T4 joint, aiming to correlate fatigue crack growth behavior with mechanical properties investigated using electron backscatter diffraction (EBSD). Notched compact tension (CT) specimens corresponding to the morphology of the stir zone (SZ), advancing side (AS), and retreating side (RS) were meticulously designed. The findings indicate that the welding process enhances the joint’s resistance to fatigue crack growth, with the base metal exhibiting a shorter fatigue life (i.e., ~105 cycles) compared to the welding zones (SZ ~ 3.5 × 105 cycles, AS ~ 2.5 × 105 cycles, and RS ~ 3.0 × 105 cycles). Crack propagation occurs within the stir zone, traversing refined grains, which primarily contribute to the highest fatigue life and lowest FCG rate. Additionally, cracks initiate in AS and RS, subsequently expanding into the base metal. Moreover, the study reveals a significant release of residual strain at the joint, particularly notable in the Structural-CT-RS (Str-CT-RS) sample compared to the Str-CT-AS sample during the FCG process. Consequently, the FCG rate of Str-CT-AS is higher than that of Str-CT-RS. These findings have significant implications for improving the reliability and performance of aerospace components. Full article
(This article belongs to the Special Issue Advances in Solid-State Welding Processes)
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