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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (28 February 2021) | Viewed by 30608

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Prof. Dr. Yutaka S. Sato

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Department of Materials Processing, Graduate School of Engineering, Tohoku University, 6-6-02 Aramaki-aza-Aoba, Sendai 980-8579, Japan
Interests: dissimilar welding and joining; friction stir welding; ultrasonic welding; welding metallurgy

Special Issue Information

Dear Colleagues,

Multi-material structures, combining various materials with different functions or properties, are significantly effective for manufacturing high-performance parts and products at low production and operational costs in modern industrial applications. In the automotive industry, for example, multi-material solutions consisting of steel, aluminum, and composites can replace traditional steel structures, resulting in the weight reduction of vehicles and the drastic improvement of fuel efficiency. The multi-material concepts bring many advantages, such as optimizing product design by matching the most-suited material to the required property, and using expensive materials with high-performance only where absolutely necessary, in the other industries.

To build multi-material structures, dissimilar-material welding and joining is required. However, the production of highly reliable multi-material structures is still difficult because many problems arising from metallurgical reactions (the formation of brittle phases), large differences in melting temperature or thermal expansion coefficient between the materials, galvanic corrosion, and so on are inevitable during the dissimilar-material welding and joining. Recently, a large number of academic studies on the welding and joining of several combinations of dissimilar materials using various low-heat-input or solid-state welding and joining processes have been contributing to the development of dissimilar-material welding and joining to create highly reliable multi-material structures, but a vast amount of research and development activities are still needed.

This Special Issue tries to deal with the recent advances in dissimilar-material welding and joining, except for welding and joining of materials with different alloy systems, regarding processing, microstructures, and properties, to develop a deep understanding of the current status and future directions of dissimilar-material welding and joining.

Prof. Dr. Yutaka S. Sato
Guest Editor

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Keywords

Dissimilar-material welding and joining processes
Microstructure
Weld (joint) properties
Dissimilar-metal welding and joining
Metal/plastic welding and joining
Weld (joint) interface
Multi-material
Low-heat-input welding and joining processes
Solid-state welding and joining processes

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Published Papers (10 papers)

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Research

14 pages, 8011 KiB

Open AccessArticle

Friction Stir Welding of AA2099-T83 and AA2060-T8E30 Aluminium Alloys with New Cr-Free Surface Treatments and Sealant Application

by Egoitz Aldanondo, Javier Vivas, Pedro Álvarez, Iñaki Hurtado and Alexandra Karanika

Metals 2021, 11(4), 644; https://doi.org/10.3390/met11040644 - 15 Apr 2021

Cited by 7 | Viewed by 3559

Abstract

The feasibility for friction stir welding (FSW) surface-treated AA2099-T83 aluminium extrusions with AA2060-T8E30 aluminium sheets in the overlap configuration and using a sealant at the interface was investigated in this work. New Cr-free surface treatments such as thin film sulphuric acid anodising (TFSAA) and sol–gel were applied to the parent materials, and a sealant was applied before applying the FSW process. FSW welds were produced using several combinations of surface treatments and sealant application with no significant influence on FSW process stability and performance. The metallographic examination of the welds showed that a good protection of the crevice was achieved with some sealant accumulation at the edges of the overlapping region. The microstructural analysis showed no sealant remnants but the presence of some oxide remnants in the stir zone (SZ) of the welds, especially in the TFSAA treated parent material cases. However, these remnants did not show any significant effect in the static pull-out strength of the joints and failures at the most stressed zone of the AA2099-T83 extrusions outside the FSW weld region were consistently obtained. Full article

(This article belongs to the Special Issue Dissimilar Material Welding and Joining)

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12 pages, 4872 KiB

Open AccessArticle

Fabrication of Roughened Electrodeposited Copper Coating on Steel for Dissimilar Joining of Steel and Thermoplastic Resin

by Susumu Arai, Ryosuke Iwashita, Masahiro Shimizu, Junki Inoue, Masaomi Horita, Takashi Nagaoka and Masami Itabashi

Metals 2021, 11(4), 591; https://doi.org/10.3390/met11040591 - 5 Apr 2021

Cited by 5 | Viewed by 3833

Abstract

Electrodeposition of a roughened copper coating onto steel was carried out to produce a bonding surface for thermoplastic resin (polyphenylenesulfide). The roughened copper film was electrodeposited using a copper sulfate bath containing polyacrylic acid (PAA). Following injection molding of the resin, the bonding strength was evaluated in a tensile lap shear strength test, followed by durability testing at high temperature and humidity (85 ± 2 °C and 85 ± 2% relative humidity, respectively) for 2000 h, and a thermal shock test (−50 °C–150 °C) for 1000 cycles. An analysis of the boundary microstructure showed that the PAA concentration had a large effect on the surface morphology of the copper film. The shear strength of the joint between the coated steel substrate and the resin was more than 40 MPa, and the bonding strength also remained above 40 MPa throughout the durability test. During the thermal shock test, although the bonding strength gradually decreased with increasing number of cycles, it remained at over 20 MPa, even after 1000 cycles. This method achieves not only high initial bonding strength, but also durability for joints between dissimilar materials such as steel and resin. Full article

(This article belongs to the Special Issue Dissimilar Material Welding and Joining)

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17 pages, 5395 KiB

Open AccessFeature PaperArticle

Surface Structuring via Additive Manufacturing to Improve the Performance of Metal and Polymer Joints

by Xin Zou, Lifu Huang, Ke Chen, Muyang Jiang, Shanyong Zhang, Min Wang, Xueming Hua and Aidang Shan

Metals 2021, 11(4), 567; https://doi.org/10.3390/met11040567 - 31 Mar 2021

Cited by 15 | Viewed by 2778

Abstract

In order to enhance the joint performance of Ti6Al4V titanium alloy (TC4) and ultra-high molecular weight polyethylene (UHMWPE) for biomedical applications, different structures were fabricated on TC4 surfaces via electron beam melting (EBM) method in this study. Macromorphologies and microinterfaces of TC4–UHMWPE joints produced via hot pressing technique were carefully characterized and analyzed. The effects of different surface structures on mechanical properties and fractured surfaces were investigated and compared. Strong direct bonding (1751 N) between UHMWPE and TC4 was achieved. The interfacial bonding behavior of TC4–UHMWPE joints was further discussed. This study demonstrates the importance of combining macro- and micromechanical interlocking, which is a promising strategy for improving metal–polymer joint performance. It also provides guidance for metal surface structuring from both theoretical and practical perspectives. Full article

(This article belongs to the Special Issue Dissimilar Material Welding and Joining)

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13 pages, 4382 KiB

Open AccessFeature PaperArticle

Characterization of Shock Wave Damages in Explosion Welded Mo/Cu Clads

by Pradeep Kumar Parchuri, Shota Kotegawa, Kazuhiro Ito, Hajime Yamamoto, Akihisa Mori, Shigeru Tanaka and Kazuyuki Hokamoto

Metals 2021, 11(3), 501; https://doi.org/10.3390/met11030501 - 18 Mar 2021

Cited by 4 | Viewed by 2768

Abstract

The shock wave damage during explosive welding has not been reported in a flyer Mo plate of the Mo/Cu clads. However, it would be an inevitable problem in group VI elements. This study was aimed to characterize the shock wave damage in the Mo plate, that is less brittle than a W plate, of explosive welded Mo/Cu clads. Cladding at low horizontal collision velocities leading to high collision angles was expected to enhance the shock wave damage, and the clads resulted in less elongation in bending tests. On the other hand, in the clads obtained at high horizontal collision velocities (HCVs) with low collision angles, their bending elongation increased significantly. The shock wave damage penetrated from the surface of a Mo plate to the Mo/Cu interface, and thus reducing thickness of a Mo plate of bending specimens increased bending plastic strain. The shock wave damage is associated with kinetic energy imparted to the flyer Mo plate, and thus loss of kinetic energy due to formation of an intermediate layer at the interface and reducing thickness of a flyer Mo plate would be very helpful for decrease of shock wave damage. Full article

(This article belongs to the Special Issue Dissimilar Material Welding and Joining)

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12 pages, 3042 KiB

Open AccessArticle

Microstructural Control of the Interface Layer for Strength Enhancement of Dissimilar Al/Cu Joints via Ni Addition during TIG Arc Brazing

by Hiroki S. Furuya, Sakiko Yabu, Yutaka S. Sato and Hiroyuki Kokawa

Metals 2021, 11(3), 491; https://doi.org/10.3390/met11030491 - 16 Mar 2021

Cited by 5 | Viewed by 2011

Abstract

Dissimilar metal joining between Al and Cu is effective for reducing the weight and cost of electrical components. In this study, dissimilar lap joining of pure Al to pure Cu with an Al-Ni filler material was conducted using tungsten inert gas (TIG) arc brazing, and the effect of Ni on the joint strength associated with the microstructure of the intermetallic compound (IMC) layer at the dissimilar interface was examined. The addition of Ni effectively increased the interfacial strength of the joints. Regardless of the addition of Ni, the joints fractured in the thick Al₂Cu layer formed at the Al/Cu interface. However, the Ni addition reduced the thickness of the IMC layer and led to the formation of Al₇Cu₄Ni particles in the weakest Al₂Cu layer. Both the thickness reduction and reinforcing Al₇Cu₄Ni particle formation are thought to contribute to the increase in joint strength of the Al/Cu dissimilar interface. Full article

(This article belongs to the Special Issue Dissimilar Material Welding and Joining)

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10 pages, 5834 KiB

Open AccessArticle

Rotary Friction Welding of Inconel 718 to Inconel 600

by Ateekh Ur Rehman, Yusuf Usmani, Ali M. Al-Samhan and Saqib Anwar

Metals 2021, 11(2), 244; https://doi.org/10.3390/met11020244 - 1 Feb 2021

Cited by 21 | Viewed by 3837

Abstract

Nickel-based superalloys exhibit excellent high temperature strength, high temperature corrosion and oxidation resistance and creep resistance. They are widely used in high temperature applications in aerospace, power and petrochemical industries. The need for economical and efficient usage of materials often necessitates the joining of dissimilar metals. In this study, dissimilar welding between two different nickel-based superalloys, Inconel 718 and Inconel 600, was attempted using rotary friction welding. Sound metallurgical joints were produced without any unwanted Laves or delta phases at the weld region, which invariably appear in fusion welds. The weld thermal cycle was found to result in significant grain coarsening in the heat effected zone (HAZ) on either side of the dissimilar weld interface due to the prevailing thermal cycles during the welding. However, fine equiaxed grains were observed at the weld interface due to dynamic recrystallization caused by severe plastic deformation at high temperatures. In room temperature tensile tests, the joints were found to fail in the HAZ of Inconel 718 exhibiting good ultimate tensile strength (759 MPa) without a significant loss of tensile ductility (21%). A scanning electron microscopic examination of the fracture surfaces revealed fine dimpled rupture features, suggesting a fracture in a ductile mode. Full article

(This article belongs to the Special Issue Dissimilar Material Welding and Joining)

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18 pages, 9374 KiB

Open AccessArticle

Microstructure and Fatigue Behavior of 2205/316L Stainless Steel Dissimilar Welded Joints

by Saúl Leonardo Hernández-Trujillo, Victor Hugo Lopez-Morelos, Marco Arturo García-Rentería, Rafael García-Hernández, Alberto Ruiz and Francisco Fernando Curiel-López

Metals 2021, 11(1), 93; https://doi.org/10.3390/met11010093 - 5 Jan 2021

Cited by 10 | Viewed by 3885

Abstract

The relation among microstructure and fatigue behavior of 2205/316L stainless steel dissimilar welded joints was investigated. Plates of 6.35 mm in thickness with a single-V joint configuration were gas metal arc welded (GMAW) in a single pass by feeding at 6 m/min an ER2209 filler wire with a heat input of 1.2 kJ/mm. Grain growth in the high temperature-heat affected zone (HT-HAZ) occurred mostly at the mid-height of the plates, delimiting the width of this region up to ~1.28 and ~0.73 mm of the 2205 and 316L plates, respectively. Dilution of the 316L plate with the ER2209 filler altered the solidification mode in this side of the weld and led to a significant content of austenite along the fusion line. Fatigue tests were performed using sinusoidal waveform at room temperature applying uniaxial cyclic loading, between constant stress limits within the elastic deformation of tension and compression (Δσ) with stress ratio R = −0.3. With stress ranges of 98% and 95% the fatigue specimens rapidly failed in much less than 10⁶ cycles. The failure crack initiated at the surface of the 316L in the HT-HAZ near the weld toe. Surface analyses of unbroken specimens before and after fatigue testing revealed a significant increment in roughness of the 316L base material owing to the formation of intrusions and extrusions. Full article

(This article belongs to the Special Issue Dissimilar Material Welding and Joining)

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9 pages, 4428 KiB

Open AccessArticle

Microstructure and Fracture Toughness of Fe–Nb Dissimilar Welded Joints

by Qiaoling Chu, Lin Zhang, Tuo Xia, Peng Cheng, Jianming Zheng, Min Zhang, Jihong Li, Fuxue Yan and Cheng Yan

Metals 2021, 11(1), 86; https://doi.org/10.3390/met11010086 - 4 Jan 2021

Cited by 4 | Viewed by 1944

Abstract

The relation between the microstructure and mechanical properties of the Fe–Nb dissimilar joint were investigated using nanoindentation. The weld metal consists mainly of Fe₂Nb, α-Fe + Fe₂Nb, Nb (s,s) and Fe₇Nb₆ phases. Radial cracks initiate from the corners of the impressions on the Fe₂Nb phase (~20.5 GPa) when subjected to a peak load of 300 mN, whereas the fine lamellar structures (α-Fe + Fe₂Nb) with an average hardness of 6.5 GPa are free from cracks. The calculated fracture toughness of the Fe₂Nb intermetallics is 1.41 ± 0.53 MPam^1/2. A simplified scenario of weld formation together with the thermal cycle is proposed to elaborate the way local phase determined the mechanical properties. Full article

(This article belongs to the Special Issue Dissimilar Material Welding and Joining)

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11 pages, 4162 KiB

Open AccessArticle

Rapid Joining of Commercial-Purity Ti to 304 Stainless Steel Using Joule Heating Diffusion Bonding: Interfacial Microstructure and Strength of the Dissimilar Joint

by K. T. Suzuki, Y. S. Sato and S. Tokita

Metals 2020, 10(12), 1689; https://doi.org/10.3390/met10121689 - 18 Dec 2020

Viewed by 2483

Abstract

A new solid-state bonding technique, Joule heating diffusion bonding, was used for the dissimilar bonding of commercial-purity Ti to 304 stainless steel within a short time without macroscopic deformation of the workpieces. The tensile strengths of the joints produced at various bonding parameters were examined at room temperature, and the microstructures of the joints and the fracture surfaces were analyzed to clarify the effect of the microstructural factors on the tensile strength of the joints. The tensile strength of the joints increased with the increase in the fraction of the sufficiently bonded interface. In the joints with the well-bonded interface, the tensile strength decreased with the increase in the thickness of the brittle Fe-Ti-type intermetallic compound layers at the joint interface. This study suggested that the high tensile strength could be achieved in the Joule heating diffusion bonded joints with the well-bonded interface where the thickness of the Fe-Ti-type intermetallic compound layers was thinner than 0.5 µm. Full article

(This article belongs to the Special Issue Dissimilar Material Welding and Joining)

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16 pages, 13182 KiB

Open AccessArticle

Numerical and Experimental Investigation of Controlled Weld Pool Displacement by Electromagnetic Forces for Joining Dissimilar Materials

by Jennifer Heßmann, Marcel Bachmann and Kai Hilgenberg

Metals 2020, 10(11), 1447; https://doi.org/10.3390/met10111447 - 29 Oct 2020

Cited by 1 | Viewed by 1698

Abstract

In order to reduce CO₂ emissions, an increasing interest in lightweight construction exists in the automotive industry, especially the multi-material-design approach. The main construction materials here are steels and aluminium alloys. Due to their different physical material properties and limited mutual solubility, these two materials cannot be joined thermally without difficulty. This paper presents a new joining approach for dissimilar materials. It uses electromagnetic displacement of a laser-generated melt pool to produce overlap joints between 1 mm steel (1.0330) and 2 mm aluminium alloy (EN AW 5754). Contactless induced Lorentz forces are generated by an alternating current (AC) magnet system. The controlled displacement of the aluminium alloy melt into the hole of the overlying steel sheet is investigated through numerical and experimental studies. The numerical results are compared with cross sections and thermocouple measurements. For the first time, it is possible to achieve a reproducible controlled melt pool displacement on thin sheets to produce overlap joints between dissimilar materials. Full article

(This article belongs to the Special Issue Dissimilar Material Welding and Joining)

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