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Special Issue "Advanced Welding Processes, Additive Manufacturing and Numerical Models"

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A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: 1 October 2024 | Viewed by 1318

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Dr. Hui Huang
E-Mail Website
Guest Editor

School of Mechanical and Electrical Engineering, Soochow University, Suzhou 215123, China
Interests: welding design; simulation; engineering software

Special Issue Information

Dear Colleagues,

Welding and additive manufacturing are key technologies in the modern manufacturing industry that have increasing needs relating to high-quality products, high-volume deposition, and high-temperature application. New type of materials and structures, such as functionally graded materials and lattice structures, can be fabricated by additive manufacturing which is superior to traditional processes. Advanced welding processes and additive manufacturing, as well as their digital twins, will greatly contribute to manufacturing technology and the process development of materials.

This Special Issue aims to highlight the latest progress on the welding process and additive manufacturing development towards the fabrication of new structures, the innovation of functional materials, and the optimization of manufacturing processes. Full-length research articles on welding technology development, weld consumables, powder material, additive manufacturing process, numerical modeling, and process monitoring and control, among other things, are welcome. The world’s leading experts in the field of welding and additive manufacturing will be invited to submit their findings. Accepted papers will be open access for the whole research community in order to increase the visibility of their innovative research findings.

Dr. Hui Huang
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

welding
additive manufacturing
process monitoring
modeling

Published Papers (3 papers)

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Research

20 pages, 12737 KiB

Open AccessArticle

Crack-Free Joining of High-Strength AA7055 Sheets by Friction Based Self-Piercing Riveting with the Aid of Numerical Design

and

J. Manuf. Mater. Process. 2023, 7(6), 216; https://doi.org/10.3390/jmmp7060216 - 01 Dec 2023

Viewed by 267

Abstract

Unique friction-based self-piercing riveting (F-SPR) was employed to join high-strength, low-ductility aluminum alloy 7055 for lightweight vehicle applications. This study aimed to maximize the joint strength of the AA7055 F-SPR joint while avoiding cracking issues due to low ductility at room temperature. A fully coupled Eulerian–Lagrangian (CEL) model was employed to predict the process temperature during F-SPR, and the temperature field was then mapped onto a 2D axisymmetric equivalent model for accelerated numerical analysis. The geometry, dimensions, and material strength of the rivet, as well as the depth of the die cavity and plunging depth, were investigated to enhance joint formation. Also, a static finite-element analysis model was developed to predict and analyze the stress distribution in the rivet under different mechanical testing loading conditions. Overall, the numerical model showed good agreement with the experiment results, such as joint formation and mechanical joint strength. With the aid of virtual fabrication through numerical modeling, the joint design iterations and process development time of F-SPR were greatly reduced regarding the goal of lightweight, high-strength aluminum joining. Full article

(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)

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22 pages, 36929 KiB

Open AccessArticle

Towards a Simulation-Assisted Prediction of Residual Stress-Induced Failure during Powder Bed Fusion of Metals Using a Laser Beam: Suitable Fracture Mechanics Models and Calibration Methods

Hannes Panzer

Daniel Wolf

Andreas Bachmann

and

Michael Friedrich Zaeh

J. Manuf. Mater. Process. 2023, 7(6), 208; https://doi.org/10.3390/jmmp7060208 - 27 Nov 2023

Viewed by 318

Abstract

In recent years, Additive Manufacturing (AM) has emerged as a transformative technology, with the process of Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) gaining substantial attention for its precision and versatility in fabricating metal components. A major challenge in PBF-LB/M is the failure of the component or the support structure during the production process. In order to locate a possible residual stress-induced failure prior to the fabrication of the component, a suitable failure criterion has to be identified and implemented in process simulation software. In the work leading to this paper, failure criteria based on the Rice-Tracey (RT) and Johnson-Cook (JC) fracture models were identified as potential models to reach this goal. The models were calibrated for the nickel-based superalloy Inconel 718. For the calibration process, a conventional experimental, a combined experimental and simulative, and an AM-adapted approach were applied and compared. The latter was devised to account for the particular phenomena that occur during PBF-LB/M. It was found that the JC model was able to capture the calibration data points more precisely than the RT model due to its higher number of calibration parameters. Only the JC model calibrated by the experimental and AM-adapted approach showed an increased equivalent plastic failure strain at high triaxialities, predicting a higher cracking resistance. The presented results can be integrated into a simulation tool with which the potential fracture location as well as the cracking susceptibility during the manufacturing process of PBF-LB/M parts can be predicted. Full article

(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)

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17 pages, 5774 KiB

Open AccessArticle

Comprehensive Investigation of Hastelloy C-22 Powder Weld Overlay on SA 240 Type 316L Using Laser Beam Welding for Enhanced Performance

Manish V. Mehta

Mrunalkumar D. Chaudhari

Rakesh Chaudhari

Sakshum Khanna

and

Jaykumar Vora

J. Manuf. Mater. Process. 2023, 7(6), 207; https://doi.org/10.3390/jmmp7060207 - 24 Nov 2023

Viewed by 424

Abstract

This article presents a comprehensive study on the application of Hastelloy C-22 powder weld overlay on SA 240 Type 316L austenitic stainless steel using the laser beam welding process. This novel combination of materials and processes was investigated for the first time, focusing on its potential utility for various industrial applications. Various testing techniques, including visual testing, hardness testing, bend testing, chemical composition analysis using optical spectroscopy, corrosion resistance assessment through the potentiodynamic polarization technique, and macro- and microstructural observation, were employed to evaluate the performance of the weld overlay. The research findings had several significant outcomes. Notably, precise control and minimal alloy mixing were achieved, as evidenced by the dilution at a remarkable height of 0.5 mm from the base metal. The laser welding process resulted in a minimal heat-affected zone and a fine columnar interdendritic microstructure, with average primary and secondary arm spacing values of 3.981 µm and 2.289 µm, respectively. Rigorous visual and bend testing confirmed the integrity of the sound welds in the overlay. Moreover, the high-quality finish of the weld overlay eliminated the need for extensive machining and finishing processes, resulting in cost reductions. This study also demonstrated primary and secondary inter-laminar spacing, leading to improved overall structural integrity. Additionally, the weld overlay exhibited excellent hardness characteristics. The current work contributes to the advancement of welding processes and provides practical solutions to enhance efficiency, cost-effectiveness, and structural performance in relevant industrial applications. Full article

(This article belongs to the Special Issue Advanced Welding Processes, Additive Manufacturing and Numerical Models)

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