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To meet the service conditions and strength requirements of turbine stator blades and the inner and outer rings of aero engine casings, CoFeNiCrMn high-entropy alloy filler was used to braze SiCf/SiC/GH536 joints. This study investigated the effects of holding time on the joints' microstructure and mechanical properties. Key phases identified in the welded joints include MoNiSi, FCC, and Cr23C6 near the composites, with brittle Ni3Si and Fe2Si intermetallic compounds forming due to filler diffusion. Optimal brazing parameters were found to be 1220 °C for 30 min with a shear strength of 64.28 MPa. The study also highlighted that increased holding time at the same temperature enhances diffusion at the joint, increasing brittle intermetallic compounds, initially improving shear strength, which then declines. Microstructural and fracture morphology analyses revealed that insufficient insulation time leads to poor welding and stress concentration at pores, causing cracks. Excessive insulation time results in joint fractures due to the brittleness of Ni3Si and Fe2Si intermetallic. Thus, joint shear strength correlates with welding quality and intermetallic compound distribution.

Studies that focus on brazing high-nitrogen steel (HNS) to high-entropy alloys (HEAs) are currently limited. In this study, the HEA Al0·3CoCrFeNi was successfully brazed to HNS using a commercial BNi-2 filler at 1080–1140 °C. The microstructure and shear strength of the Al0·3CoCrFeNi/HNS brazed joints were observed and evaluated. The typical microstructure of the brazed joint was HNS/infiltration layer/reaction layer/Ni(s,s) (containing NiAl3)/reaction layer/infiltration layer/Al0·3CoCrFeNi. The higher brazing temperature and longer holding time promoted the diffusion of B as a brazing seam with homogeneous Ni(s,s), and more intergranular Cr-rich borides formed in the base materials. The optimized shear strength attained 549.2 MPa after the joint brazed at 1120 °C for 15 min, and ductile fracture occurred in the reaction zone. The insufficient and excessive diffusion of B resulted in residual Cr–B compounds in the brazing seam and excess borides in the HNS, respectively, which negatively affected shear strength. All the joints showed poor corrosion resistance following immersion in a 3.5 wt% NaCl solution because the excess Cr-rich compounds resulted in decreased Cr content in the surrounding matrix. Therefore, Ni-based fillers without B were more suitable for obtaining Al0·3CoCrFeNi/HNS joints with a favorable corrosion resistance.

Integration of aluminum (Al) and titanium (Ti) alloys offers an effective approach to sustainable and high-quality development of the automotive and aviation industries. However, challenges arise when welding Al alloys to Ti alloys due to the formation of detrimental intermetallic compounds at the interface. With the implementation of ultrasonic vibrations, the temperature and strain rate were both increased during Al/Ti friction stir welding (FSW), leading to the formation of an amorphous interlayer, instead of intermetallic compound (IMC), at the interface. The interfacial microcracks were eliminated in the ultrasonic vibrations assisted friction stir welding (UVFSW). There were Ti particles separated from the Ti substrate and dispersed in the Al alloy, thereby resulting in a more gradual and moderate evolution of the interfacial microstructure. Due to the improved interfacial microstructure with ultrasonic vibrations, the lap shear strength was almost twice that of the conventional FSW welds within same welding conditions. Meanwhile, ultrasonic vibrations also improved the fabrication efficiency with a higher optimal traversing speed. The failure mode shifted from interface separation of FSW welds to a shear dimple fracture of the UVFSW welds, demonstrating the better plasticity and reliability of the UVFSW Al/Ti dissimilar joints.

Residual stress is the main hindrance to achieve a robust ceramic/metal brazed joint. In this study, yttria stabilized zirconia (YSZ) particles was fabricated into solid-state transformation composite filler, which was proposed as a new strategy to strengthen Ti3SiC2/Cu brazed joint. After detailed characterization conducted on YSZ particles and brazed joint, the abnormal expansion properties of YSZ and its strengthening brazed joint mechanism were clarified. The content of Y2O3 in YSZ had significant effects on the phase transformation of ZrO2 from tetragonal to monoclinic. When 3 mol.% Y2O3 was added, the maximum phase transformation occurred at about 500 ◦C, half of brazing temperature, during the cooling process. The phase transformation of ZrO2 effectively released residual stress in the joint, which was induced by both temperature changes and residual stress. The abnormal volume expansion during phase transformation decreased the thermal mismatch of brazed joint further to strengthen brazed joint.

Aluminum/steel structures are widely proposed for weight reduction in aviation, aerospace, and automotive industries, whereas the applications of aluminum/steel structures are still limited due to the unreliable welding related to the intermetallic compounds. In this study, an amorphous layer was in-situ formed at the aluminum/steel interface, replacing the intermetallic compounds, and strengthening the welds. The effects of the plunge depth on the microstructure and mechanical properties of the Al/steel friction stir welds were further investigated. The amorphous phase was only formed when the welding tool was plunged to the interface precisely. Once the plunge depth was further increased, the amorphous layer would grow over the critical thickness of 18 nm and, subsequently, be replaced by the FeAl3 and FeAl. Different interfacial microstructure led to the different strength and fracture characteristics. The ultimate load of 6237 N was achieved with the in-situ formed amorphous layer, and it was improved by 45 %, as compared to the previous results.

Wire-arc additive manufacturing (WAAM) was used in aeronautical engineering due to its low equipment cost and ability to create complex shapes. However, the fatigue behavior of WAAM titanium alloy, specifically for low cycle fatigue (LCF), was poorly studied. This paper investigated the microstructure and mechanical behavior of WAAM TC17 in both vertical and horizontal orientations. Fully reversed LCF tests were conducted on specimens with varying strain amplitudes from ±0.4 % to ±1.2 %. The results found that the ultimate tensile and yield strength were similar for both vertical and horizontal samples, but the elongation in the horizontal orientation was approximately 60 % lower than that in the vertical orientation. Considering the cyclic loading behavior, both vertical and horizontal samples exhibited cyclic softening characteristics at high strain amplitudes (0.8%–1.2 %). Additionally, the cyclic softening rate (CSR) of horizontal samples exhibited a higher than that of vertical samples at high strain amplitude. The LCF cracks of WAAM TC17 were initiated from the surface and internal defects of the samples. The LCF performance of the horizontal samples was found to decrease than that of vertical samples. Specifically, the fatigue performance of the horizontal samples is lower by 36.7 % compared to the vertical samples when the number of cycles is 103.

This paper developed an innovative pressure-free contact reaction brazing technique that facilitated joining ceramics at low temperatures. Using this method, a semi-solid TiNiCuNb filler was employed to join C/C–SiC composite and Ti60 alloy. By facilitating elements’ diffusion through the partial liquid of semi-solid TiNiCuNb alloy, Ti could be introduced into this alloy without pressure, and the complete melting was achieved above 950 °C. Based on this, Ti60 alloy was joined to C/C–SiC composite below its β-transus temperature. Significant reaction differences between C/C and SiC with filler were found, mainly due to the different solubility and diffusion characteristics of C and Si in liquid filler. SiC exhibited higher sensitivity to temperature changes and was more prone to overreaction to induce defects. At 1010 °C, the maximum shear strength of 22.5 MPa was obtained due to the moderate reaction of both C/C and SiC with filler. This work contributed to manufacturing lightweight brake systems.

Laser texturing is a promising technology with wide-ranging applications in surface processing. In this study, a nanosecond laser was used to ablate the surface of Q355 steel, creating grooves of varying depths by different processing times. Satisfactory Al/Steel joints were obtained under different groove depths (0 μm, 6 μm, 26 μm and 56 μm). Interfacial microstructure evolutions were investigated and the observed results indicated that introduction of texture would enhance interfacial specific surface area, promote degree of atomic diffusion, thicken interfacial IMCs (intermetallic metallic compounds) while maintain interfacial reaction (η-Fe2(Al,Si)5 + θ-Fe(Al,Si)3). Numerical simulations results illustrated that existence of texture would reduce interfacial peak residual stress, homogenize residual stress distribution and induce compressive stress in the groove. Highest strength of 111 MPa with the fracture mode of tough-brittle compound fracture was produced in the joint when laser texturing processing times were 20, which was nearly 40 % higher compared to the untreated joint (80 MPa). This study provides a novel method to improve joints mechanical properties for laser welding-brazing of Al/Steel system, which may also provide a theoretical reference for the application of other dissimilar metal systems.

Laser powder-bed fusion (LPBF) possesses unique advantages in manufacturing complex structures. The mechanical properties of thin-wall structures are crucial for the application. This study investigates the influence of wall thickness on defects and mechanical properties of LPBF Hastelloy X (HX) superalloy. As the wall thickness decreases from 1.5 mm to 0.25 mm, the diameter of sub-grains inside the molten pool increases, exhibiting a progressively enhanced //transverse direction (TD) texture in thin wall structure. Meanwhile, decreasing wall thickness leads to increased porosity and cracks due to unstable molten pool and higher residual stress. The crack initiates at columnar to equiaxed transition (CET) position and propagates along the building direction (BD). The tensile strength of the LPBF HX specimens in the horizontal and vertical directions is 773.5 MPa and 642.1 MPa with thickness of 1.5 mm, respectively, while the elongation of both specimens is close to 35%. When the wall thickness decreases to 0.25 mm, the elongation significantly decreases due to the evolution of microstructure anisotropy and the cracks along the BD, reaching 10.1% and 24.3% for horizontal and vertical specimens. This work illustrates the defects, microstructural evolution and the mechanical properties anisotropy in thin-wall structures of LPBF HX, providing a foundation for adjusting and optimizing the performance of subsequent thin-wall printing processes.

Owing to restrictions on forming dimensions, laser powder bed fusion (LPBF) components will continue to require laser welding in the future. The post-weld thermal cracking of LPBF-Haynes 230 superalloys has become a key issue hindering their assembly in service. In this study, it was found that both the continuous TCP phase and M5Si3 silicides near the crack have a large interface strain with the matrix. Replacing the C and Si atoms with B atoms at the crack reduces the melting point of the carbides and silicides at the grain boundaries (GBs), thereby inducing solidification cracking under the residual tensile stress in the weld waist. The weldability of the alloy is influenced by the grain characteristics of the base metal (BM). Compared to parallel welds, vertical welds are inherited from the BM and exhibit smaller grains. Moreover, by reducing the heat treatment (HT) time and temperature, the grain size and grain misorientation of the BM are reduced and inherited into the weld. The GB area of the weld increases by 37% and the GB energy decreases by 7.3%, increasing the resistance to crack extension. In addition, the decreased HT temperature inhibits the carbide growth at the GBs, thereby reducing the interface strain between the matrix and carbides in the heat-affected zone and correspondingly its cracking sensitivity. This study provides theoretical guidance for improving the laser weldability of LPBF superalloys and will help accelerate the successful application of LPBF superalloy assemblies in engines.

External magnetic field has been employed to improve appearance and suppress defects in the single laser or arc welding, and its physical mechanism in magnetic-field-assisted single laser or arc welding has been clearly clarified. However, few studies on the physical processes in magnetic-field-assisted laser-arc hybrid welding (MFA-LAHW) are conducted and its influencing mechanism is unclear. In this research, a comprehensive three-dimension numerical model is established to investigate the keyhole dynamics and weld pool behaviors in MFA-LAHW under the effect of different magnetic flux density. The results suggest that the interaction between a lower magnetic flux density (≤30 mT) and welding current is induced due to the existence of arc. Compared to the magnetic-field-assisted laser beam welding (MFA-LBW), this interaction induces a stronger Lorentz force up to the order of magnitude of 105 N/m3. The weld pool width is reduced while its length and height are increased because the Lorentz force facilitates the backward flow of thermal fluid, increasing the heat transfer from the keyhole and droplet to the rear weld pool edge. Moreover, the steady magnetic field improves the keyhole stability. The deform on keyhole rear wall brought by the droplet and vortex is suppressed, and keyhole size is widened under steady magnetic field, which reduced keyhole collapse. Furthermore, the comparative analysis with the case in MFA-LBW is carried out and the MFA-LAHW is verified to be more valuable for medium-thickness aluminum alloy. This work provides the underlying physics understanding of MFA-LAHW, which will broaden the application value of LAHW.

To achieve laser direct welding of glass and metal without optical contact is hard, owing to the large difference in thermal expansion and thermal conductivity between glass and metal and an insignificant melting area. In this study, the high-power picosecond pulsed laser was selected to successfully weld the aluminosilicate glass/6061 aluminum alloy with a gap of 35 ± 5 μm between glass and metal. The results show that the molten glass and metal diffuse and mix at the interface. No defects such as microcracks or holes are observed in the diffusion mixing zone. Due to the relatively large gap, the glass collapsed after melting and caulking, resulting in an approximately arc-shaped microcrack between modified glass and unmodified glass or weakly modified glass. The shape of the glass modification zone and thermal accumulation are influenced by the single-pulse energy and linear energy density of the picosecond laser during welding, resulting in variations in the number and size of defects and the shape of the glass modification zone. By reasonably tuning the two factors, the shear strength of the joint reaches 15.98 MPa. The diffusion and mixing at the interface and the mechanical interlocking effect of the glass modification zone are the main reasons for achieving a high shear strength of the joint. This study will provide reference and new ideas for the laser transmission welding of glass and metal in the non-optical contact conditions.

The arc torch angle greatly affected the deposition characteristics in the wire arc additive manufacturing (WAAM) process, and the relation between the droplet transition behavior and macrostructure morphology was unclear. This work researched the effect of torch angle on the formation accuracy, droplet transition behavior and the mechanical properties in the WAAM process on a ZL205A aluminum alloy. The results suggested that at the obtuse torch angle, part of the energy input was used to heat the existing molten pool, which was optimized for the longer solidification period of the molten pool. Therefore, the greater layer penetration depth at 100° resulted in the improved layer-by-layer combination ability. The obtuse torch angle was associated with the better formation accuracy on the sidewall surface due to the smaller impact on the molten pool, which was influenced by both the arc pressure and droplet impact force. The eliminated pores were optimized for the mechanical properties of depositions at a torch angle of 100°; thus, the tensile strength and elongation attained maximum values of 258.6 MPa and 17.1%, respectively. These aspects made WAAM an attractive mode for manufacturing large structural components on ZL205A aluminum alloy.

The detection of keyhole-induced pore positions is a critical procedure for assessing laser welding quality. Considering the detection error due to pore migration and noise interference, this research proposes a regional prediction model based on the time–frequency-domain features of the laser plume. The original plume signal was separated into several signal segments to construct the morphological sequences. To suppress the mode mixing caused by environmental noise, variational modal decomposition (VMD) was utilized to process the signals. The time–frequency features extracted from the decomposed signals were acquired as the input of a backpropagation (BP) neural network to predict the pore locations. To reduce the prediction error caused by pore migration, the effect of the length of the signal segments on the prediction accuracy was investigated. The results show that the optimal signal segment length was 0.4 mm, with an accuracy of 97.77%. The 0.2 mm signal segments failed to eliminate the negative effects of pore migration. The signal segments over 0.4 mm resulted in prediction errors of small and dense pores. This work provides more guidance for optimizing the feature extraction of welding signals to improve the accuracy of welding defect identification.

Laser powder-bed fusion (LPBF) technique has broad prospects in lightweight structure designing and rapid manufacturing. In this study, solution treatment (ST), hot isostatic pressing (HIP), and HIP+ST were performed on crack-free LPBF Hastelloy X. The corresponding microstructure, precipitates, and mechanical properties after different heat treatments were compared to identify the critical factor affecting the fracture mechanisms at room and elevated temperature. The specimens exhibited a high recrystallization degree under all heat treatment conditions, which had little contribution to the performance differences. However, different holding time and cooling rate led to variations in carbide distribution. Granular M6C carbides were formed in ST specimens, while linear M23C6 carbides were formed in HIP specimens. In contrast, barely no carbides were observed in the HIP+ST specimen. At room temperature, all specimens showed similar tensile strength, while the ranking of elongation was HIP+ST=ST>HIP. The decreased elongation of the HIP specimen was attributed to the linear carbides at grain boundaries. However, the ranking of elongation was presented as HIP>HIP+ST>ST at high temperature. Carbides at grain boundaries coarsened and affected the crack propagation behaviors. The HIP specimen had appropriate carbide size, which restricted the crack propagation within a single grain boundary, forming wedge-shaped cracks. When the carbide was too small or oversized, crack propagated along the grain boundaries and reduced the plasticity. This work demonstrated that the carbide size was a critical factor for the performance control. In addition, the room temperature performance was insufficient for evaluating suitable heat treatment conditions for LPBF Hastelloy X.

Herein, prepared Ti40–Ni40–Nb20 (at. %) alloy was utilized as a filler metal to join Al2O3 ceramic. The effect of brazing temperature and holding time on the interfacial microstructure evolution and shear strength of joints were analyzed systematically. The results demonstrated that AlNi2Ti, Ni6Nb7 and layered Ni2Ti4O formed adjacent to Al2O3 ceramic. The microstructure of Al2O3 joint brazed at 1200 °C for 10 min was Al2O3/AlNi2Ti + Ni6Nb7 + Ni2Ti4O/Ti2Ni/TiNi + Nb solid solution (Nbss) eutectic + (Ti,Nb)2Ni/Ti2Ni/Ni2Ti4O + Ni6Nb7 + AlNi2Ti/Al2O3. As brazing temperature or holding time raised, the Ni2Ti4O layer nearby Al2O3 ceramic, AlNi2Ti and Ni6Nb7 developed tremendously whereas TiNi + Nbss eutectic structure gradually increased and tended to coarsen. Eventually, the TiNi + Nbss eutectic structure and (Ti,Nb)2Ni in brazing seam were replaced gradually by bulk Ni6Nb7 because of the depleted Ti element. The shear strength of joints was first increased and then decreased with the increasing of the temperature/holding time. The Al2O3/Al2O3 joints brazed at 1200 °C for 10 min received the maximum shear strength of 93.2 MPa, and the joints fractured primarily at the brazing seam/Al2O3 interface.

The Al butt-lap joints are widely applied in China Railway High-speed (CRH) trains body joints. However, the gaps caused by the thermal deformation in Al butt-lap joints lead to the lack penetration or over penetration. To predict the penetration state of laser welds in Al butt-lap joints with different gaps, this work investigated the correlation between the plasma plume morphology and penetration state monitored by high-speed imaging system and the vertical gap and horizontal gap were utilized as intermediary. The ensemble experience mode decomposition (EEMD) was used to obtain the frequency features of plasma plume morphology. A support vector machine (SVM) model combined with EEMD was then established to classify the different penetration state, which adopted the original signals at time-domain and the mode decomposition signals at frequency-domain as input. The EEMD-SVM accuracy of 97.98% was the highest among the EMD-SVM of 86.44% and the SVM of 58.15%. The EEMD-SVM obtained both high Accuracy and Recall when the quantity of positive and negative samples were utmost different. The classification of the EEMD-SVM model was the most superior among the EMD-SVM model and SVM model. This proposed method provided a novel and accurate approach to perform process monitoring and penetration defects detection during laser welding of butt-lap joints.

Obtaining a reliable NiTi to Ti6Al4V dissimilar joint exhibiting NiTi's superelasticity can provide design flexibility in aerospace and biomedical fields via integrating distinct material benefits. However, this materials couple is vulnerable to severe embrittlement due to the development of excessive intermetallic compounds (IMCs), namely Ti2Ni. Pd-free and Pd-interlayered NiTi-Ti6Al4V laser joints were evaluated for their microstructure, compositional changes, thermodynamic mechanism, and mechanical properties. The presence of Pd constrained the formation of Ti2Ni IMC, and NiTi-Ti6Al4V joints with excellent mechanical properties demonstrating superelastic behavior were achieved for the first time. The tensile strength and rupture strain of the Pd-added NiTi-Ti6Al4V joint improved more than twofold, reaching 520 MPa and 5.6%, respectively. During cyclic tensile testing, the Pd-added joint demonstrated superelasticity and a comparable irrecoverable strain to NiTi (1 versus 0.65%). Multiscale characterization revealed that the fraction of Ti2Ni decreased from 83 to 10% near the NiTi boundary and 24 to 6% at the weld center compared to the Pd-free joint. The superior thermodynamic formation tendency of Ti-Pd compounds over Ti2Ni IMC favored their development, and thus Ti-Pd and NiTi compounds dominated the fusion zone (FZ) at the expense of Ti2Ni IMC, explaining the improved mechanical performance of the Pd-added joint.

Abstract The laser welded joint of 2000MPa cold rolled annealed hot pressed steel (PHS) is easy to break during cold rolling. In this paper, the laser welding method is used to butt weld four kinds of PHS2000 with a thickness of 3.5mm. The four kinds of PHS2000 steel are added with elements of 0% Nb, 0.04% Nb, 0.06% Nb + Cr and 0.08% Nb + Cr. The microstructure of the four kinds of welded joints is compared and analyzed. The mechanical properties of the four kinds of joints are compared through hardness test and tensile test. The results show that after adding 0.04% Nb, residual austenite appears in the weld zone and fully quenched zone, the width of columnar crystal decreases, the average hardness of the weld zone decreases from 595HV to 408HV, and the tensile strength increases from 608MPa to more than 800MPa. For chromium containing steel, the increase of niobium content can reduce the size of columnar crystal in weld zone.

This paper investigated the effect of repair welding on the microstructure, mechanical properties, and high cycle fatigue properties of S355J2 steel T-joints in orthotropic bridge decks. The test results found that the increase in grain size of the coarse, heat-affected zone decreased the hardness of the welded joint by about 30 HV. The tensile strength of the repair-welded joints was reduced by 20 MPa compared to the welded joints. For the high cycle fatigue behavior, the fatigue life of repair-welded joints is lower than that of the welded joints under the same dynamic load. The fracture positions of toe repair-welded joints were all at the weld root, while the fracture positions of the deck repair-welded joints were at the weld toe and weld root, with the same proportion. The fatigue life of toe repair-welded joints is reduced more than that of deck repair-welded joints. The traction structural stress method was used to analyze fatigue data of the welded and repair-welded joints, and the influence of angular misalignment on was considered. The fatigue data with and without AM are all within the ±95% confidence interval of the master S-N curve.

The work aimed to investigate the effects of alternating magnetic field on the microstructure, mechanical properties and plasma characteristics during laser-MIG hybrid welding of HG785D steel. The weld appearance was improved and the weld depth was significantly enhanced by an alternating magnetic field. The same microstructure type of lath martensite (LM) was obtained in the arc zone and laser zone of all hybrid welded joints. However, grains in the arc zone were significantly refined and the ratio of high-misorientation angles was increased under alternating magnetic field. The average grain size in the arc zone reduced from 4.60 to 3.67 μm with a magnetic flux density of 30 mT. The average microhardness of the arc part and the laser part increased from 356 and 378 to 388 and 393 HV, respectively. The grain refinement and increased ratio of high-misorientation angles led to an improvement in low-temperature impact toughness. The low-temperature impact toughness was 184 J with a magnetic flux density of 30 mT, which was 95.7% higher than that without the alternating magnetic field. Additionally, the shielding effect of the hybrid plasma was suppressed with the magnetic flux density of 10–30 mT, leading to an increase in the penetration ability of hybrid heat sources and weld depth. However, the penetration ability of the hybrid heat source was no longer enhanced with a further increase in magnetic flux density.

The influence of heat treatment on microstructure evolution and mechanical properties of TiB2/Al 2024 composites fabricated by laser-powder directed energy deposition (DED) were investigated. The results showed that the addition of TiB2 resulted in a significant grains refinement with random orientation. Compared with DED-Al 2024, a lot of network-like θ-Al2Cu phases was generated in the as-deposited TiB2/Al 2024 composite, leading to low plasticity. After 10h solution treatment, the θ phase disappeared, the thermally stable block T-Al20Cu2Mn3 phase was formed and the ultimate tensile strength (UTS) and elongation improved due to solution strengthening. During the aging process, Cu element was precipitated and semi-coherent θ’ phase was generated, improving the effect of Orowan strengthening. The composite material reached the maximum UTS of 453.65 MPa after 10h aging. The yield strength (YS) enhanced with the increase of aging time. After 15h aging, the YS and microhardness reached the maximum of 245.73 MPa and 133.50HV, respectively. This research provides a theoretical basis for the repair and manufacture of Al 2024 alloy and composite parts.

Oscillating laser welding of 2-mm-thick 6061-T6 aluminum alloy and AISI304 steel in overlap configuration was performed under various oscillation amplitudes of 0, 3, and 5 mm. The experimental results indicated that the welding window of Al/steel dissimilar joints was improved with increasing oscillation amplitudes. The beam oscillation broadened weld width and interfacial bonding width while reducing weld depth. In the joint produced under 0-mm oscillation, a multi intermetallic compound (IMC) layer formed with a thickness of about 90 μm. In the joint produced under 3-mm oscillation, the IMC layer with the compositions of η-Fe2Al5+block-shaped θ-Fe4Al13) was obtained and its corresponding thickness reduced to 20 μm. When the oscillation amplitude further increased to 5 mm, only a η-Fe2Al5+little θ-Fe4Al13 layer with a thickness of 5 μm generated. Simulation results for the temperature history indicated that an oscillating laser beam would disperse laser energy, restraining the steel penetrating. Besides, dispersed heat energy depressed the melting of lower aluminum sheets and interfacial element diffusion. Thus, the formation of IMCs was suppressed. The limited IMCs and increased bonding width led to an improvement in the tensile–shear properties. The maximum fracture load of the joint under 5-mm oscillation was 185 N/mm, which was twice higher than that of joints welded without beam oscillation. Less Al atoms dissolved into the fusion zone under beam oscillation, resulting in lower microhardness and better toughness. Fracture locations changed from the fusion zone to the interface due to weakened steel penetration and improved toughness.

In this study, laser-arc hybrid welding of 5A06 aluminum alloys was performed firstly. To improve the surface quality of welded joints, ultrasonic peening (UP) process was employed. The influence of different peening needle velocities on surface microstructure and properties was investigated. The results indicated that UP produced protrusions and grooves on treated surface of welded joints. EBSD analysis showed that grains in UP-treated surface layers was refined from 100 to 50 μm. Improved dislocation structure was observed via TEM analysis. Increasement in full width at half maximum (FMHW) and Bragg angle of diffraction peaks in XRD analysis further demonstrated the formation of fine grains. The surface microhardness increased by 38.9% from 92.6 to 132 HV due to the work hardening effects. In addition, UP-treated welded joints possessed better wear resistance. After UP process, a 50% decrease in wear rate was obtained. The wear mechanism changed from adhesive to abrasive wear for the UP-treated joints. Besides, the possibility of corrosion initiation and the corrosion rate of UP-treated joints were lower than those of non-treated joints implying better corrosion resistance.

Fiber laser welding of QP980 steel and press-hardened 22MnB5 steel in butt configuration was performed in this study. The effect of heat input on microstructure evolution and mechanical properties of dissimilar joint was investigated. Laser power employed was varied from 1.6 to 2.4 kW while welding speed was kept constant at 2 m/min. The microstructure of fusion zone (FZ) was changed with the increasing laser power. Martensite and few bainite were observed when laser power ranged from 1.8 to 2.2 kW. Out of this range, the microstructure in FZ consisted of mixed structure of martensite and ferrite. Transformation from liquid phase to ferrite was promoted by Al-Si coating on the surface of press-hardened 22MnB5 steel. Heat affected zones (HAZs) of dissimilar joint were composed of martensite and bainite. Softened zone (SZ) appeared at the HAZ of 22MnB5 steel due to tempering behavior. The hardness of SZ and QP980 steel base metal declined with microstructure evolution. The fracture occurred at QP980 base metal when dissimilar joints were produced at laser power of 1.8 and 2.0 kW. When laser power reached 2.2 kW, the tensile samples failed at SZ owing to the increased softening degree. With further increasing laser power, the weakest region was FZ since ferrite declined the whole joint strength. A better Erichsen value was obtained at 2.0 kW (4.04 mm), which was balanced by more crash energy absorption and better deformation resistance.

Al/steel dissimilar welds were obtained by friction stir lap welding (FSLW) with an Al interlayer, which was fabricated by friction surfacing (FS). In present study, the tool pin was totally plunged into the Al plate and interlayer without stirring steel, which avoided the tool wear. The Al plate and interlayer were remarkably intermixed as pin length increased. A diffusion layer, instead of the intermetallic layer, was found at the Al/steel interface, indicating the enhanced atomic migration and related interfacial bonding. The maximum failure load of the joints of 2.8 kN was reached when the 2.5 mm pin tool was used. The heterogeneous microstructure, which was caused by the intermixing, was responsible for the fracture, according to the fracture profiles. Necking and dimples were depicted from the fractographies, indicating that the joints were failed by plastic fracture. Keywords: Al/steel dissimilar joining, Friction surfacing, Friction stir welding, Microstructure, Mechanical properties

Dissimilar materials brazing of Ti2AlNb alloy to GH99 superalloy is of great pragmatic importance in the aerospace field, especially the lightweight space aircraft components manufacturing. In this work, TiZrCuNi amorphous filler alloy was used as brazing filler, and experiments were carried out at different brazing temperatures and times to investigate the changes in interfacial structures and properties of the joints. The typical interfacial microstructure was Ti2AlNb alloy/B2/β/Ti2Ni (Al, Nb) + B2/β + (Ti, Zr)2(Ni, Cu) + (Ti, Zr)(Ni, Cu)/(Cr, Ni, Ti) solid solution + (Ni, Cr) solid solution/GH99 superalloy when being brazed at 1000 °C for 8 min. The interfacial microstructure of the joints was influenced by diffusion and reaction between the filler alloy and the parent metal. The prolongation of brazing process parameters accelerated the diffusion and reaction of the liquid brazing alloy into both parent metals, which eventually led to the aggregation of (Ti, Zr)2(Ni, Cu) brittle phase and increased thickness of Ti2Ni (Al, Nb) layer. According to fracture analyses, cracks began in the Ti2Ni (Al, Nb) phase and spread with it as well as the (Ti, Zr)2(Ni, Cu) phase. The joints that were brazed at 1000 °C for 8 min had a maximum shear strength of ~216.2 MPa. Furthermore, increasing the brazing temperature or extending the holding time decreased the shear strength due to the coarse Ti2Ni (Al, Nb) phase and the continuous (Ti, Zr)2(Ni, Cu) phase.

In this study, C-plane (0001) sapphire was successfully brazed to titanium using AuSn20 filler metal, following metallization on the surface of the sapphire with Sn-3Ti (wt.%). At 1000 °C, Sn-3Ti had good wettability on the surface of the sapphire, with the lowest equilibrium contact angle of 57°. The reaction phases in the joints were identified, and the typical interfacial microstructure of the brazed joint brazed at 550 °C for 30 min was titanium substrate/Au-Sn-Ti layer/Ti6Sn5 + AuSn2 + AuSn4 + massive Au-Sn-Ti/TiO phase/sapphire. The shear test was utilized to evaluate the bonding strength of the titanium/sapphire joints. The highest shear strength reached 18.7 MPa when brazed at 550 °C for 35 min. The crack was initiated at the sapphire/brazing seam interface and propagated into the Au-Sn-Ti reaction layer.

1060 aluminum–T2 copper dissimilar lap joints were produced by friction stir spot welding (FSSW) with various dwell time. All the joints possess a Cu hook extruded upward from the lower Cu plate into the upper Al plate with intermetallic compounds (IMCs) developed on its interface. Increasing the dwell time produced an increase in the heat input during welding and promoted IMC growth. At short dwell time, the interface was characterized by the interruptedly distributed CuAl2 layer partially mingled with CuAl phase. However, continuous CuAl2–CuAl–Al4Cu9 laminated layer developed at the interface at longer dwell time. IMC formation sequence for CuAl2, CuAl and Al4Cu9 were determined by thermodynamic principles. Microhardness was quite different in different zones. Hardness values in the stir zone (SZ) were much higher due to the dispersively distributed IMC particles and the refined grains. Joints with better tensile properties have a higher penetration depth of the hook into the upper Al plate as well as a continuous IMC layer at the hook interface. Results of fracture path analysis indicated that all the fracture initiated at the CuAl2–CuAl or CuAl2–Al interface and then extended along the IMC layer at the hook interface. The dispersed IMC particles in the SZ provided an alternative path for crack extension when strong metallurgical bonding was achieved at the hook interface. Keywords: Friction stir spot welding, Aluminum/copper dissimilar metals, Microstructure evolution, Mechanical properties, Fracture path.

The purpose of this study was to investigate the wetting behavior and interfacial reactions of Sn-Ti alloys, which has been widely applied to join ceramics with metals, on Si3N4 substrates. The isothermal wetting process of Sn-xTi alloys (x = 0.5, 1.0, 1.5, 2.0 and 2.5 wt.%) on Si3N4 was systematically studied from 1223 K to 1273 K through sessile drop methods. The microstructures of the interface were characterized by X-ray diffraction (XRD) and microscope (SEM). The active Ti element remarkably enhanced the wettability of Sn-xTi melts on Si3N4 substrates because of the formation of metallic reaction layers (Ti5Si3 and TiN). With the Ti content rising, thicker Ti5Si3 layer formed on the TiN phase inducing a lower equilibrium contact angle. The value of the lowest contact angle was 6°, which was obtained in the Sn-2.0Ti/Si3N4 system at 1273 K. Larger Ti5Si3 grains were found in Sn-2.5Ti melt and a higher final contact angle was obtained. Lower temperature increased the final contact angle and slowed down the spreading rate. The formation of reaction products was calculated thematically, and the spreading kinetics was calculated according to the reaction-driven theory. The spreading behavior of Sn-Ti alloy on Si3N4 ceramic was composed of rapid-spreading stage and sluggish-spreading stage. The calculated activity energy of spreading was 395 kJ/mol. Eventually, the wetting process of Sn-2.0Ti/Si3N4 system was successfully elucidated. These results provide significant guidance information for the brazing between metals and Si3N4 ceramic.

This study aimed to conduct a comparative study on the microstructure and mechanical performance of 5083, 6005A and 7N01 Al joints used in China Railway High-speed (CRH) trains. We connected 10 mm-thick plates by three-layer and three-pass gas metal arc welding (GMAW). The results indicated that 6005A and 7N01 Al joints were more sensitive to grain boundary liquation in the partially melted zone (PMZ) than 5083 Al joins. Besides, recrystallization was obtained in heat-affected zones (HAZ). The 5083 Al joints experienced the most severe recrystallization and the grain size changed from 6.32 (BM) to 32.44 (HAZ) μm duo to intracrystalline strain induced by cold-rolled processes. The 7N01 Al alloys experienced the lowest extent of recrystallization and the grain size increased from 5.32 (BM) to 22.31 (HAZ) μm. Furthermore, significant precipitate evolution in the HAZ was observed. Original thin β” precipitates dissolved in HAZ of 6005A Al joints and transformed to the softer β phase. However, less precipitation transition was examined in 5083 and 7N01 Al joints. The precipitates’ evolution produced a softening region in HAZ of 6005A joints where the hardness was only 55 HV. The microhardness profile of the other two Al joints was less affected. The tensile strength of 5083, 6005A, and 7N01 Al alloy joints reached 323, 206 and 361 MPa, respectively. The 5083 Al and 6005A Al joints failed at HAZ near the fusion line while 7N01 Al joints failed at the fusion zone owing to the high strength of the base metal. The liquation, coarse grains by recrystallization, and precipitate evolution all decreased local strength, resulting in the fracture at HAZ.

The brazing of Titanium alloy to Aluminum alloy is of great significance for lightweight application, but the stable surface oxide film limits it. In our work, the surface oxide film was removed by the ion bombardment, the deposited Cu layer by magnetron sputtering was selected as an interlayer, and then the contact reactive brazing of TC4 alloy to Al7075 alloy was realized. The microstructure and joining properties of TC4/Al7075 joints obtained under different parameters were observed and tested, respectively. The results revealed that the intermetallic compounds in the brazing seam reduced with the increased brazing parameters, while the reaction layer adjacent to TC4 alloy continuously thickened. The shear strength improved first and then decreased with the changing of brazing parameters, and the maximum shear strength of ~201.45 ± 4.40 MPa was obtained at 600 °C for 30 min. The fracture path of TC4/Al7075 joints changed from brittle fracture to transgranular fracture, and the intergranular fracture occurred when the brazing temperature was higher than 600 °C and the holding time exceeded 30 min. Our work provides theoretical and technological analyses for brazing TC4/Al7075 and shows potential applications for large-area brazing of titanium/aluminum.

Titanium and zirconia (ZrO2) ceramics are widely used in biomedical fields. This study aims to achieve reliable brazed joints of titanium/ZrO2 using biocompatible Au filler for implantable medical products. The effects of brazing temperature and holding time on the interfacial microstructures and mechanical properties of titanium/Au/ZrO2 joints were fully investigated by scanning electron microscopy (SEM), energy-dispersive spectrometry (EDS) and X-ray diffraction (XRD). The results indicated that the typical interfacial microstructure of the titanium/Au/ZrO2 joint was titanium/Ti3Au layer/TiAu layer/TiAu2 layer/TiAu4 layer/TiO layer/ZrO2 ceramic. With an increasing brazing temperature or holding time, the thickness of the Ti3Au + TiAu + TiAu2 layer increased gradually. The growth of the TiO layer was observed, which promoted metallurgical bonding between the filler metal and ZrO2 ceramic. The optimal shear strength of ~35.0 MPa was obtained at 1150 °C for 10 min. SEM characterization revealed that cracks initiated and propagated along the interface of TiAu2 and TiAu4 reaction layers.

Using composite filler is a very potential way to braze dissimilar material, especially braze metals with ceramics. The composite filler which is added varieties of high temperature alloy, carbon fiber and ceramic particles has a suitable coefficient of thermal expansion. The application of composite filler can release the residual stress caused by mismatch of thermal expansion coefficient in the brazing joints and improve the overall performance significantly. According to the traditional classification method of composite materials, the composite filler is divided into micron-reinforced composite filler and nano-reinforced composite filler, of which the feature and research status are discussed in this text. According to the influence of different size reinforced phases on microstructure and mechanical property of the brazing joints, nano-reinforced composite filler has more uniform and better structure compared with micron-reinforced composite filler, and higher joint strengh can be obtained by using it. However, the reinforced mechanism is still an open question, and will become the key area of the future research work.

Welding and joining of titanium aluminides is the key to making them more attractive in industrial fields. The purpose of this review is to provide a comprehensive overview of recent progress in welding and joining of titanium aluminides, as well as to introduce current research and application. The possible methods available for titanium aluminides involve brazing, diffusion bonding, fusion welding, friction welding and reactive joining. Of the numerous methods, solid-state diffusion bonding and vacuum brazing have been most heavily investigated for producing reliable joints. The current state of understanding and development of every welding and joining method for titanium aluminides is addressed respectively. The focus is on the fundamental understanding of microstructure characteristics and processing–microstructure–property relationships in the welding and joining of titanium aluminides to themselves and to other materials.

Medical titanium and alumina (Al2O3) bioceramic are widely utilized as biomaterials. A reliable brazed joint of titanium and alumina was successfully obtained using biocompatible Au foil for implantable devices in the present study. The interfacial microstructure and reaction products of titanium/Au/Al2O3 joints brazed under different conditions were investigated by scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). In this study, the typical interfacial microstructure of the titanium/Au/Al2O3 joint was titanium/Ti3Au layer/TiAu layer/TiAu2 layer/TiAu4 layer/Au + granular TiAu4 layer/TiOx phase/Al2O3 ceramic. With increasing brazing temperature or holding time, the thicknesses of Ti3Au + TiAu + TiAu2 layers adjacent to the titanium substrate increased gradually. Shear tests indicated that the joint brazed at 1115 °C for 3 min exhibited the highest shear strength of 39.2 MPa. Typical fracture analysis displayed that the crack started at the Al2O3 ceramic and propagated along the interface of TiAu2 and TiAu4 reaction layers.

In this study, reliable Ti2AlNb/high-Nb-containing TiAl alloy (TAN) joints were achieved by diffusion bonding. The effects of bonding temperature and holding time on the interfacial microstructure and mechanical properties were fully investigated. The interfacial structure of joints bonded at various temperatures and holding times was characterized by scanning electron microscopy (SEM), energy dispersive spectrometer (EDS) and X-ray diffraction (XRD). The results show that the typical microstructure of the Ti2AlNb substrate/O phase/Al(Nb,Ti)2 + Ti3Al/Ti3Al/TAN substrate was obtained at 970 °C for 60 min under a pressure of 5 MPa. The formation of the O phase was earlier than the Al(Nb,Ti)2 phase when bonding temperature was relatively low. When bonding temperature was high enough, the Al(Nb,Ti)2 phase appeared earlier than the O phase. With the increase of bonding temperature and holding time, the Al(Nb,Ti)2 phase decomposed gradually. As the same time, continuous O phase layers became discontinuous and the Ti3Al phase coarsened. The maximum bonding strength of 66.1 MPa was achieved at 970 °C for 120 min.