FeCrAl alloys are among the best and most mature accident tolerant fuel cladding candidates produced to date, due to their superior combination of mechanical properties and stability at elevated temperatures. For fuel cladding applications, these materials are drawn into tubes with plugs welded to the ends. The mechanical properties of such welds and the impact on cladding performance have not been fully investigated. A novel mesoscale mechanical test and a variety of microscale tests were performed to evaluate a range of properties including nanoindentation hardness, compression and shear yield strengths, and tensile strengths and elongations. Micromechanical testing generally matched the trends of the larger mesoscale testing, with nanoindentation reproducing the trend the best, although some discrepancies existed in regions with low dislocation content. Mesoscale tensile testing showed good correlation with macroscale tests and revealed that the plug heat-affected zone possessed the lowest strength and ductility. This indicated that failure would occur first in or near this region.

This article overviews the ultrasonic welding process, a solid-state joining method, using the example of welding of a magnesium alloy as well as the joining of magnesium alloys in general. In situ high-speed imaging and infrared thermography were utilized to study interfacial relative motion and heat generation during ultrasonic spot welding of AZ31B magnesium (Mg) alloys. A postweld ultrasonic nondestructive evaluation was performed to study the evolution of local bond formation at the faying interface (contact surface of the joint between the top and bottom Mg sheets) at different stages of the welding process. Two distinct stages were observed as the welding process progresses. In the early stage, localized reciprocating sliding occurred at the contact faying interface between the two Mg sheets, resulting in localized rapid temperature rise from the localized frictional heating. Microscale (submillimeter) bonded regions at the Mg–Mg faying surface started to form, but the overall joint strength was low. The early-stage localized bonds were broken during the subsequent vibrations. In the later stage, no relative motion occurred at any points of the faying interface. Localized bonded regions coalesced into a macroscale joint that was strong enough to prevent the Mg–Mg interface from further breakage and sliding. With increasing welding time, the bonded area continued to increase.

With growing demand for better fuel economy for automobiles, multimaterial solutions are increasingly being utilized in the automotive industry for reducing weight in the vehicle body structure. This poses challenges in terms of joining dissimilar metals, especially those with vastly different properties such as aluminum to steel joining. General Motors has developed a new resistance spot-welding technique for dissimilar materials using a multi-ring domed (MRD) electrode and multiple solidification weld schedules to address this challenge. Originally developed for aluminum to aluminum resistance spot welding, this technology is being deployed as the mainstream aluminum joining solution to leverage existing infrastructure and workforce competency in resistance spot welding. With the recent expansion of MRD technology to aluminum to steel resistance spot welding, there is an ever-greater need to experimentally verify the quality of each aluminum to steel resistance spot-weld application with limited time and resources. Nondestructive evaluation (NDE) would enable the transfer of resistance spot-welding technology to dissimilar aluminum to steel joints. This article describes the current state of the art of aluminum to steel resistance spot welding and the challenges in developing a robust NDE process for this technology.

Vaporizing foil actuator welding is a form of impact welding, which can be carried out without the use of chemical explosives. Operating at smaller length scales, but with similar driving pressures as explosive welding, vaporizing foil actuator welding is capable of welding a wide variety of advanced and dissimilar metal combinations. With negligible heating developing during the process, thermal distortion does not occur, and the base-metal properties are retained in the weld. In this article, vaporizing foil actuator welding of an automotive grade aluminum and steel pair is discussed. A currently functional and complete welding system that can be used for research as well as low volume production is also discussed.

Lightweighting of vehicles and portable structures is an important undertaking. Multimaterial design is required to achieve conflicting design targets such as cost, stiffness, and weight. Friction stir welding (FSW) variants, such as friction stir dovetailing and friction stir scribe, are enabling technologies for joining of dissimilar metals. This article discusses how FSW variants are capable of joining aluminum to steel in particular. The characteristics of metallurgical bonding at the dissimilar materials interface are strongly affected by weld temperature. Control of FSW process temperature enables metallurgical bonding with suppressed formation of intermetallics at the dissimilar materials interface, resulting in improved mechanical properties relative to competing techniques. Temperature control is thus a powerful tool for process development and ensuring weld quality of dissimilar materials welds.

Oxide inclusions such as gray spots are the main defects caused by rail flash butt welding (FBW). An appropriate temperature field and upsetting process are essential for the extrusion of joint impurities. This study constructed a thermomechanical coupling model for the solid-state upsetting process of rail FBW through a combination of finite element simulation and experiment. Subsequently, the effects of different temperature fields and upsetting parameters on the extrusion behavior of impurities were studied. The results show that when the lateral deformation of the joint is not considered, selecting the appropriate upsetting length and increasing the width of the high-temperature plastic zone are beneficial for the extrusion of harmful impurities. Moreover, using variable speed upsetting or increasing the speed of the early upsetting facilitates the extrusion of impurities. However, the impurities in the deeper areas of the rail are difficult to move, and they easily form gray spot defects if the oxide inclusions remain.

In this paper, a path planning algorithm for robotic systems with excess degrees of freedom (DOF) for welding of intersecting pipes is presented. At first step, the procedure of solving the inverse kinematics considering system kinematic redundancy is developed. The robotic system consists of a 6 DOF robotic manipulator installed on a railed base with linear motion. Simultaneously, the main pipe is able to rotate about its longitudinal axis. The system redundancy is employed to improve weld quality. Three different simulation studies are performed to show the effect of the robotic system kinematic redundancy to plan a better path for the welding of intersecting pipes. In the first case, it is assumed that robotic manipulator base and main pipe are fixed, and the path is planned only with manipulator joints motion. In the second case, only the robot base is free to move and the main pipe is fixed, and in the third case, the main pipe is free to rotate together with the base of the manipulator. It is seen that kinematic constraints according to the system’s redundancy will help to plan the most efficient path for the welding of complex pipe joints.

Nowadays the different industries is searching continuous improvements in the welding processes of the components of its products, in order to avoid the disadvantages obtained in the past by joining their parts through conventional fusion welding processes, affecting their microstructural development and consequently decreasing the principal mechanical properties. The friction-stir welding process is a solid state technique which does not reach the melting point of the material, promoting the plasticization of the metal by controlling its microstructure and mechanical behavior. However, the after mentioned advantages are the result of an adequate control of the process parameters, so that the aim of the present investigation is to study the microstructural and mechanical development of 5052-H32 butt joints welded by FSW process using a high wear resistance tool (PCBN tool) as well as the mechanical behavior suffered.

Different materials have been welded by laser beam. This process allows to obtain high quality welds with lower thermal effect. Laser beam welding produces narrow and high penetration welds without filler material. However, this process modifies the mechanical and microstructural properties of the welded joints. Therefore, this is currently a research topic, mainly using Advanced High Strength Steel (AHSS). These materials are used in the automotive industry. As a result, it is important to study the thermometallurgical and mechanical behavior of welded steels. In addition, a tool used to approximate the thermal effect in the fusion zone (FZ) and heat affected zone (HAZ) has been the computational numerical simulation. In this work, two butt joints of DP600 steel plates of 200 mm x 150 mm and 2 mm thickness with different welding sequences were simulated using the SYSWELD finite element software. The results of both coupons were compared and it was determined that the distortion and residual stresses decreased in the second coupon by applying a different welding sequence with equal heat input.

In this research it was experimentally analyzed the effect of the parameters of the Pulsed Micro Laser Welding Process Nd:YAG on the microstructural behavior of a nickel base superalloy (IN-738). For this purpose, different laser welding tests were performed on samples subjected to different heat treatment conditions obtained from the gas turbine blades. The influence of the power and the speed welding of the applied process and heat treatment condition on the weld geometry, microstructure and mechanical properties was determined. The microstructures of the obtained welds were characterized by scanning electron microscopy and Vickers hardness tests. In general, alternatives to homogenize and rejuvenate the microstructure of the base material are proposed in order to avoid the formation and propagation of cracks. The results are discussed mainly in terms of the present phases and decomposition of carbides, which considerably affect the weldability of the IN-738 superalloy. This study provides useful information for the subsequent restoration of the 2nd step turbine blades by using of the Laser Welding Process Nd:YAG.

Hybrid welding is a process used in aeronautical materials to obtain benefits such as complete penetration, narrow heat affected zones, reduce filler material used, among others, mainly due the ability of the process to control filler-metal additions and heat input in materials such as steels, titanium and aluminum alloys. Recently a new industrial revolution is taken place called manufacturing 4.0, the aeronautical and automotive industry have a great interest in all the pillars which making it up, one of the principal pillars is the big data analysis such as welding parameters applied in advances welding processes. The present work describes a welding optimization applying non-dominated sorting genetic algorithm-III (NSGA-III) to find and predict depth penetration (DP) and mechanical properties, specifically ultimate tensile strength (UTS) in ASTM 1520 steel welded by a hybrid laser arc welding with the objective to improve the weld quality. A diverse experiment were used in order to obtain a suitable model, considering welding speed (WS), wire feed rate (WF), voltage (V), current (A) and laser power (P). The experimental results demonstrated that the pareto front values obtained by NSGA-III improve the DP and UTS. Microstructural phases and mechanical properties were discuss to complement the values obtained and chosen.

Even though AA 7075 is an aluminum alloy with high mechanical properties, it is not often applied in manufacturing. This is so, because it is considered as very difficult to produce defect free welded joints. This is so, because this alloy has a tendency to hot cracking. The metallurgical problems that appear during welding of AA 7075 have not been fully solved but they have been reduced by applying alloys such as: 4043 and 5356 as filler metals. However, in literature there is little information about the metallurgical effects of these types of filler metals applied in arc welded joints of AA7075. This is especially true for Tungsten Inert gas welding. Therefore, this work is focused in comparing the microstructure and Vickers microhardness in weldments of AA 7075 with ER4043, ER5356 and AA7075 as filler metals. Besides, a set of welded joints with the three different filler metals were quenched after welding in order to modify the final microstructure. The results were evaluated by microstructural analysis focused on the Heat Affected Zone and Vickers microhardness and they were compared among them.

AZ31 magnesium alloy sheets were A-TIG-welded through a coating of flux, which contained different ratios of Ce powder and nano-sized SiC as reinforcement particles and equal mass of TiO2 as activating fluxes. The microscopic analysis results illustrated that relatively low content of Ce in the reinforcement particles caused the formation of Al3Ce precipitates and refined the grains of α-Mg phase together with β-Mg17Al12 and SiC particles. The increase in microhardness and ultimate tensile strength of the joints was 6.2% and 19.2%, respectively, when reinforcement particles contain 20 wt% Ce compared to the joints coated without Ce. By studying the electrochemical test results, when using 20 wt% Ce + 80 wt% SiC as reinforcement particles, the corrosion current density was the lowest and the corrosion resistance reached the largest value, reflecting the improvement of corrosion property of the joint affected by Ce element.

This article showcases details on enumerative information of dissimilar aluminum (Al) to steel welds manufactured using different friction-based welding processes with an emphasis on the description of the manufacturing process, influence of parameters, microstructural variations, formation of intermetallic compounds (IMCs), and variations in mechanical properties. Friction-based welding processes such as friction welding, friction stir welding, hybrid friction stir welding, friction stir spot welding, friction stir spot fusion welding, friction stir scribe welding, friction stir brazing, friction melt bonding, friction stir dovetailing, friction bit joining, friction stir extrusion, and friction stir assisted diffusion welding are analyzed for the formation of dissimilar Al–steel joints. It can be summarized that friction-based joining processes have great potential to obtain sound Al–steel joints. The amount of frictional heat applied decides the type and volume fraction of IMCs that subsequently affects mechanical joint properties. Process variations and novel process parameters can enhance joint properties.

The ignimbrites of the northeast Niğde area, which are subdivided into the Lower, Middle and Upper ignimbrites on the basis of their compositional and stratigraphical characteristics, display textural variations from the base to the top. A large proportion of these ignimbrites have been altered and recrystallized by the processes of compaction, welding and devitrification, and as a result of volatile movement. The alteration and recrystallization processes include four stages: hydration, glassy and spherulitic stages accompanied by vapour-phase crystallisation. In the early phases of devitrification, detailed shard shapes are easily recognisable with the scanning electron microscope, but as alteration proceeds clarity of detail disappears because compaction results in collapse of the structure of the rock. Spherulitic and vapour-phase crystallisation usually involves the growth of alkali feldspar and cristobalite. These later stages are more common in the Upper Ignimbrite than the Middle and Lower ignimbrites.

Welding was successfully used in the fabrication of low pressure steam turbine rotors for nuclear power plants. In this paper, the local brittle zone of the welded joint in NiCrMoV steel with heavy section was investigated by cross-zone fracture toughness test and the effect of martensite–austenite constituent in the simulated reheated zone of welds with different second peak temperature on toughness was analyzed. The results showed that the crack propagated in unstable manner in the reheated zone of welds where the martensite–austenite constituent promoted the initiation and propagation of the crack. The fine structure of martensite–austenite constituent contained retained austenite, martensite, and martensite–austenite mixture microstructure. The impact toughness deteriorated drastically in the incomplete phase transition zone for the simulated reheated zone of welds related to the formation of mixture microstructure in which large blocky martensite–austenite constituent at prior austenite grain boundaries and inside the grains were distributed in the shape of network.

The purpose of this work is to study the effect of SiO2- and Al2O3-NPs on the microstructure and mechanical properties of the weld bead (WB) created by a process of Submerged Arc Welding (SAW) between two AISI 1025 steel plates. Also it was necessary consider the chemical compositions of slags and burned fluxes, in order to determine the elements that are deposited and contribute in the final microstructure of WB. The welding materials to form each WB were a M12K electrode, a commercial fused flux (CFF) and AISI 1025 steel plates bevelled at 45°. In addition SiO2- or Al2O3-NPs an ethylic alcohol mixture were applied directly to the beveled surfaces, just before the SAW process, which was carried out according to the AWS A5.17 norm. Microstructural and phase changes at the Heat Affected Zone (HAZ) and Welding Zone (WZ) were analysed by metallographic Optical and Scanning Electron Microscopies. The mechanical properties of the WBs were determined through Tensile, Charpy impact and Vickers Hardness tests. By means of metallography of WBs, it was determined that the length of the AF needles increases in 113 and 183 % when adding SiO2- or Al2O3-NPs, respectively. Related to the mechanical properties of the WB, the tensile and yield strength decreases with both additions, SiO2- or Al2O3-NPs. The microhardness at WZ was found to decrease by adding such oxide-NPs. Moreover, the impact energy absorbed by the WBs increases approximately by 83 or 57% due to SiO2- or Al2O3-NPs addition, respectively.

High-Mn Twinning Induced Plasticity (TWIP) steels are an excellent alternative in the design of structural components for the automotive industry. The TWIP steels application allows weight reduction, maintaining the performance of vehicles. Nowadays the research works focused on TWIP steel weldability are relative scarce. It is well-known that weldability is one of the main limitations for industrial application of TWIP steel. The main goal of this research work was studied the effect of heat input on the microstructural changes generated in a TWIP steel microalloyed with Ti. A pair of welds were performed through Gas Tungsten Arc Welding (GTAW) process. The GTAW process was carried out without filler material, using Direc Current Electrode Negative (DCEN), tungsten electrode EWTh-2 and Ar as shielding gas. The microstructure and average grain size in the fusion (FZ) and heat affected zone (HAZ) were determined by light optical metallography (LOM). Elements segregation in the FZ was evaluated using point and elemental mapping chemical analysis (EPMA) by Scanning Electron Microscopy and Electron Dispersive Spectroscopy (SEM-EDS). Phase transformations were evaluated using X-ray diffraction (XRD). Finally, the hardness were measured by means of Vickers microhardness testing (HV500). The results show that the FZ is characterized by a dendritic solidification pattern. Meanwhile, the HAZ presented equiaxed grains in both weld joints. On the other hand, the TWIP-Ti steel weldments did not present austenite phase transformations. Nevertheless, the FZ exhibited variations in the chemical elements distribution (Mn, Al, Si and C), which were higher as the heat input increases. Finally, the heat input reduced the microhardness of TWIP-Ti steel weld joints. Although post-welding hardness recovery was detected, which is associated with precipitation of Ti second-phase particles.

Underwater welding using reactive materials pre-deposited at the junction surfaces as a self-contained, in-situ ignitable heat source mitigates external power and gas supply requirements. Consequently, lending itself to robotic implementation eliminating the cost along with health and safety hazards of human welder-divers. This project reports on lap joining of aluminum sheets with sandwiched commercial reactive Ni-Al multilayers that are perforated to allow for melt fusion under compression upon ignition, in saline and deionized water as well as air for comparison. Finite-element thermal simulations are employed to study the resulting welding temperature field and melt conditions. Infrared pyrometry and thermocouple measurements during welding were used to validate the computational simulations. The lap joints are subjected to standard shear testing, and comparable compliance, strength and toughness values of the welds are assessed for underwater and dry joints. Scanning electron (SEM) of the weld sections reveal rapidly melting and solidifying microstructures of the parent metal, with minimal melt flow and perfusion of nickel aluminide aggregates from the reacted multilayers, and no signs of cavitation.

The welding heat input has been pointed out as a main limiting factor for TWinnig Induced Plasticity (TWIP) steel weldability. Scarce research works have been focused on the study of application and effects of the Gas Tungsten Arc Welding (GTAW) process in the TWIP steel, especially in higher thickness plate. In this research work was conducted a detailed analysis of a butt weld joint performed in plates of TWIP steel microalloyed with titanium (TWIP-Ti) of 6.3 mm thickness. The autogenous GTAW process with low heat input was applied. The analysis considered grain size measurements, second phases identification, post-weld mechanical properties (microhardness) and the welding thermal field. A Finite Element Model (FEM), validated through experimental results, allowed correlating metallurgical results with the thermal field. Likewise, the phases prediction carried out by means of JMatPro 9.0 software during solidification process as well as the estimation of particle precipitation were in good agreement with the experimental results. These predictive diagrams were calculated taking into account the TWIP-Ti steel chemical composition, the grain size measured in critical weld regions and experimental cooling rates. The low heat input improved the microstructural conditions in the heat affected zone (HAZ) whose average grain size and precipitate particles, like (C, N)Ti, promoted good mechanical properties as compared to the base material (as-solution condition). Some particles like Al2O3 y MnS produced microporosities in the HAZ. Despite this, the weld joint did not present hot cracking in the FZ-HAZ interface.