Application of laser in seam welding of dissimilar steel to aluminium joints for thick structural components

Laser welding-brazing technique, using a continuous wave (CW) fibre laser with 8000 W of maximum power, was applied in conduction mode to join 2 mm thick steel (XF350) to 6 mm thick aluminium (AA5083-H22), in a lap joint configuration with steel on the top. The steel surface was irradiated by the laser and the heat was conducted through the steel plate to the steel-aluminium interface, where the aluminium melts and wets the steel surface. The welded samples were defect free and the weld micrographs revealed presence of a brittle intermetallic compounds (IMC) layer resulting from reaction of Fe and Al atoms. Energy Dispersive Spectroscopy (EDS) analysis indicated the stoichiometry of the IMC as Fe2Al5 and FeAl3, the former with maximum microhardness measured of 1145 HV 0.025/10. The IMC layer thickness varied between 4 to 21 μm depending upon the laser processing parameters. The IMC layer showed an exponential growth pattern with the applied specific point energy (Esp) at a constant power density (PD). Higher PD values accelerate the IMC layer growth. The mechanical shear strength showed a narrow band of variation in all the samples (with the maximum value registered at 31.3 kN), with a marginal increase in the applied Esp. This could be explained by the fact that increasing the Esp results into an increase in the wetting and thereby the bonded area in the steel-aluminium interface

Insights into galvanic corrosion behavior of Ti-Cu dissimilar joint: Effect of microstructure and volta potential

The effect of microstructure on corrosion behavior of a solid-state explosion welded Ti-Cu bimetal is investigated by means of alternating current-direct current (AC-DC) electrochemical measurements, optical microscopy, scanning electron microscopy, and scanning Kelvin probe force microscopy (SKPFM). The results indicate that the titanium regions in the welding interface, local melted zone (LMZ), and LMZ-Cu interface are potential sites for initiation of corrosion attacks. SKPFM mapping clearly shows that before exposure of the sample to a 3.5% NaCl corrosive solution and at the beginning of the exposure, the Cu side of the bimetal has a higher Volta potential in comparison to that of the Ti region, and thus acts as a cathode. Electrochemical measurements also confirm that titanium acts as an anode and copper as a cathode, in the first moments of immersion, in accordance with macroscopic observations and SKPFM results. However, by growing a passive layer of titanium oxide and titanium hydroxide on the Ti side after about 1 h exposure to the corrosive medium, the titanium side becomes nobler and the polarity arrangement in the galvanic couple reverses

Optimization of different welding processes using statistical and numerical approaches – A reference guide

Welding input parameters play a very significant role in determining the quality of a weld joint. The joint quality can be defined in terms of properties such as weld-bead geometry, mechanical properties, and distortion. Generally, all welding processes are used with the aim of obtaining a welded joint with the desired weld-bead parameters, excellent mechanical properties with minimum distortion. Nowadays, application of design of experiment (DoE), evolutionary algorithms and computational network are widely used to develop a mathematical relationship between the welding process input parameters and the output variables of the weld joint in order to determine the welding input parameters that lead to the desired weld quality. A comprehensive literature review of the application of these methods in the area of welding has been introduced herein. This review was classified according to the output features of the weld, i.e. bead geometry and mechanical properties of the welds

Impact Welding of Materials

Recent industrial criteria increasingly require the production of multi-material components. However, the manufacturing requirements of these components are not met by conventional welding techniques. Alternative solid-state technologies, such as impact-based processes, must be considered. The impact welding family is composed of several processes, such as explosion welding, magnetic pulse welding, vaporizing foil actuator welding, and laser impact welding. These processes present very different length scales, providing the impact welding family with a broad applicability range. A sample of the cutting-edge research that is being conducted on the multidisciplinary field of impact welding is presented in this book

Recent Developments in Non-conventional Welding of Materials

Welding is a technological field that has some of the greatest impact on many industries, such as automotive, aerospace, energy production, electronics, the health sector, etc. Welding technologies are currently used to connect the most diverse materials, from metallic alloys to polymers, composites, or even biological tissues. Despite the relevance and wide application of traditional welding technologies, these processes do not meet the demanding requirements of some industries. This has driven strong research efforts in the field of non-conventional welding processes. This Special Issue presents a sample of the most recent developments in the non-conventional welding of materials, which will drive the design of future industrial solutions with increased efficiency and sustainability

Future Armour Materials and Technologies for Combat Platforms

The ultimate goal of armour research is to create better armour for battle worthy combat plat forms such as main battle tanks, infantry combat vehicles and light combat vehicles. In each of these applications, the main aim boils down to one of the two things; either reduce the weight without sacrificing protection or enhance the performance at same or even reduced weight. In practice, these ambitions can be fulfilled only if we have with us, appropriate improved armour materials, advanced and innovative technologies and also improved designs, which enable us to use them for creating next generation armour modules. Armour systems have progressed through improvements in metallic, ceramic and lightweight (low areal density) composite materials. Similarly, the advances in development of explosive reactive armour (ERA) and non-explosive reactive armour (NERA) have generated efficient armour system against contemporary high explosive antitank ammunition and missile threats for the armoured vehicles. Yet, to achieve armour performance exceeding that of the current light combat vehicles and main battle tanks, further advancements in armour materials, systems, and survivability technologies are required for new vehicular systems that weigh significantly less than the present combat platforms. Various approaches and advancements in the metallic and composite armour materials, ERA and NERA systems to improve the survivability of armoured vehicles in the futuristic multi-spectral battlefield scenarios are described

Nanoparticle-enabled phase control for arc welding of unweldable aluminum alloy 7075.

Lightweight materials are of paramount importance to reduce energy consumption and emissions in today's society. For materials to qualify for widespread use in lightweight structural assembly, they must be weldable or joinable, which has been a long-standing issue for high strength aluminum alloys, such as 7075 (AA7075) due to their hot crack susceptibility during fusion welding. Here, we show that AA7075 can be safely arc welded without hot cracks by introducing nanoparticle-enabled phase control during welding. Joints welded with an AA7075 filler rod containing TiC nanoparticles not only exhibit fine globular grains and a modified secondary phase, both which intrinsically eliminate the materials hot crack susceptibility, but moreover show exceptional tensile strength in both as-welded and post-weld heat-treated conditions. This rather simple twist to the filler material of a fusion weld could be generally applied to a wide range of hot crack susceptible materials