Application of ultrasonic vibrations in welding and metal processing: A status review

Microwave processing of materials has emerged as a new method for processing of a variety of materials in the recent years. Microwaves have been used effectively with significant advantages, particularly in food processing and chemical synthesis. They are also found to be efficient for processing polymers, ceramics, polymeric composites, and ceramic composites. The physics of interaction of microwaves with characteristically different materials is not yet explored well; consequently, there are challenges in microwave processing of metal-based materials. Industrial processing of bulk metal is yet to be popular in spite of the fact that the feasibility of metal powder sintering was demonstrated a few decades ago. This article provides a summary of fundamental aspects of microwave processing of metal-based materials and their interaction with metallic materials. The processing challenges have been surveyed; developments in terms of techniques and tooling have been analyzed. Possible effects of microw...

A Review of Research Trends in Microwave Processing of Metal-Based Materials and Opportunities in Microwave Metal Casting

The study of dissimilar metals’ welding is an important issue due to their increasing applications in many industrial fields. Welding of dissimilar metals is challenging because of the formation of large residual stress and brittle intermetallic compounds (IMCs). In order to solve this problem, intermediate interlayers were used to eliminate or inhibit the formation of brittle intermetallic reaction layers in many welding techniques, such as diffusion bonding, laser welding, electron beam welding, and other welding techniques. The aim of this paper is to review the recent progress of dissimilar metals’ welding methods and mechanisms with interlayer to offer a basis for the following research. The work discussed several criteria for the selection of interlayer, such as physical properties, metallurgical compatibility, mode, and thickness of the interlayer. Then, formation enthalpy, Gibbs energy of formation (ΔG), and brittleness of the IMCs, as well as welding parameters, were also discussed. Simultaneously, the present work had proposed a design guideline for the selection of interlayer in dissimilar metals’ welding to acquire a welded joint with good quality.

A review on dissimilar metals’ welding methods and mechanisms with interlayer

Friction stir welding exploits its solid state process behaviour to join aluminum to steel, which differs in thermal and mechanical properties, and where combination of these metallic alloys by fusion welding prompts a deleterious reaction as a result of the melting and resolidification phases. This review investigates the distinction and characterization of aluminum to steel joints made by this welding method. An attempt to address sub-techniques into three categories i.e., diffusion, plunging, and annealing, is made. Steel fragments spattered at the weld zone, weld defects, sharp difference in grain size distribution, and the formed phases of the intermetallic layer and its thickness are discussed, these factors and the process welding parameters are significantly influenced the joint’s strength of this welding method.

Characteristics of aluminum-to-steel joint made by friction stir welding: A review

The effect of changing chemical composition on dissimilar Mg/Al friction stir welded butt joints using zinc interlayer

Improving weld strength of arc-assisted ultrasonic seam welded Mg/Al joint with Sn interlayer

Microstructure and properties of Mg/Al joint welded by gas tungsten arc welding-assisted hybrid ultrasonic seam welding

Joining of magnesium and aluminum via arc-assisted ultrasonic seam welding with Sn/Zn composite interlayer

A novel rotating wire GMAW process to change fusion zone shape and microstructure of mild steel

6061 aluminium alloy and AZ31B magnesium alloy was successfully joined together with the addition of Zn interlayer by gas tungsten arc welding assisted hybrid ultrasonic seam welding. The effects of Zn interlayer on the microstructure and mechanical properties of the joints were investigated in detail. The results indicated that the Zn interlayer could restrain the formation of brittle Mg–Al IMCs, which were replaced by Mg–Zn IMCs. The maximum lap strength of the joints with Zn interlayer was ∼16.25 MPa, which was ∼30% increase over the joints without Zn interlayer. All the joint failures occurred by the interface mode rather than the pullout mode at the Mg/Zn interface.

Liu Jihou

Papers

Improving weld strength of arc-assisted ultrasonic seam welded Mg/Al joint with Sn interlayer

Microstructure and properties of Mg/Al joint welded by gas tungsten arc welding-assisted hybrid ultrasonic seam welding

Joining of magnesium and aluminum via arc-assisted ultrasonic seam welding with Sn/Zn composite interlayer

A novel rotating wire GMAW process to change fusion zone shape and microstructure of mild steel

Arc assisted ultrasonic seam welding of Mg/Al joints with Zn interlayer