Determination of the Actual Stress–Strain Diagram for Undermatching Welded Joint Using DIC and FEM

This paper presents new methodology for determining the actual stress–strain diagram based on analytical equations, in combination with numerical and experimental data. The first step was to use the 3D digital image correlation (DIC) to estimate true stress–strain diagram by replacing common analytical expression for contraction with measured values. Next step was to estimate the stress concentration by using a new methodology, based on recently introduced analytical expressions and numerical verification by the finite element method (FEM), to obtain actual stress–strain diagrams, as named in this paper. The essence of new methodology is to introduce stress concentration factor into the procedure of actual stress evaluation. New methodology is then applied to determine actual stress–strain diagrams for two undermatched welded joints with different rectangular cross-section and groove shapes, made of martensitic steels X10 CrMoVNb 9-1 and Armox 500T. Results indicated that new methodology is a general one, since it is not dependent on welded joint material and geometry.     

Fatigue Performance of Metal–Composite Friction Spot Joints

Friction spot joining is an alternative technique for joining metals with polymers and composites. This study investigated the fatigue performance of aluminum alloy 2024/carbon-fiber-reinforced poly(phenylene sulfide) joints that were produced with friction spot joining. The surface of the aluminum was pre-treated using various surface treatment methods. The joined specimens were tested under dynamic loading using a load ratio of R = 0.1 and a frequency of 5 Hz. The tests were performed at different percentages of the lap shear strength of the joint. Three models—exponential, power law, and wear-out—were used to statistically analyze the fatigue life of the joints and to draw the stress–life (S–N) curves. The joints showed an infinite life of 25–35% of their quasi-static strength at 10⁶ cycles. The joints surpassing 10⁶ cycles were subsequently tested under quasi-static loading, showing no considerable reduction compared to their initial lap shear strength.     

Structural Response of Bonded Joints between FRP Composite Strips and Steel Plates

This paper presents the outcomes of an experimental and numerical study performed on epoxy-bonded single lap joints (SLJs) between carbon fiber-reinforced polymer (CFRP) composite strips and steel elements. For the experimental program, 34 specimens were prepared by varying the type of the composite strip and the type of adhesives and their thicknesses; all specimens were loaded in axial tension up to failure. The specific failure mechanisms were identified and commented on the basis of the performed tests, and the load–displacement curves were plotted. Additionally, the strain distributions along the bond lengths at different load stages, the shear stress–displacements (slip) variations and the stress–strain distributions for the CFRP strips were plotted and investigated. The numerical simulations, based on 3D finite element method (FEM) analysis, provided consistent results, in good agreement with the experimental ones for all parameters that were investigated and discussed in this paper.     

The Performance of CR180IF and DP600 Laser Welded Steel Sheets under Different Strain Rates

The presented research background is a car body manufacturer’s request to test the car body’s components welded from dissimilar steel sheets. In view of the vehicle crew’s protection, it is necessary to study the static and dynamic behavior of welded steels. Therefore, the influence of laser welding on the mechanical and dynamical properties, microstructure, microhardness, and welded joint surface roughness of interstitial free CR180IF and dual-phase DP600 steels were investigated. Static tensile tests were carried out by using testing machine Zwick 1387, and dynamic test used rotary hammer machine RSO. Sheet steel was tested at different strain rates ranging from 10⁻³ to 10³ s⁻¹. The laser welds’ microstructure and microhardness were evaluated in the base metal, heat-affected zone, and fusion zone. The comprehensive analysis also included chemical analysis, fracture surface analysis, and roughness measurement. The research results showed that the strain rate had an influence on the mechanical properties of base materials and welded joints. The dynamic loading increases the yield stress more than the ultimate tensile strength for the monitored steels, while the most significant increase was recorded for the welded material.     

Effects of Different Types of Interlayers on the Interfacial Reaction Mechanism at the Cu Side of Al/Cu Lap Joints Obtained by Laser Welding/Brazing

The influence of tin foil and Ni coatings on microstructures, mechanical properties, and the interfacial reaction mechanism was investigated during laser welding/brazing of Al/Cu lap joints. In the presence of a Zn-based filler, tin foil as well as Ni coating strengthened the Al/Cu joints. The tin foil only slightly influenced the joint strength. It considerably improved the spreading/wetting ability of the weld filler; however, it weakened the bonding between the seam and the Al base metal. The Ni coating considerably strengthened the Al/Cu lap joints; the highest tensile strength was 171 MPa, which was higher by 15.5% than that of a joint without any interlayer. Microstructure analysis revealed that composite layers of Ni₃Zn₁₄–(τ₂ Zn–Ni–Al ternary phase)–(α-Zn solid solution)–Al₃Ni formed at the fusion zone (FZ)/Cu interface. Based on the inferences about the microstructures at the interfaces, thermodynamic results were calculated to analyze the interfacial reaction mechanism. The diffusion of Cu was limited by the Ni coating and the mutual attraction between the Al and Ni atoms. The microstructure comprised Zn, Ni, and Al, and they replaced the brittle Cu–Zn intermetallic compounds, successfully strengthening the bonding of the FZ/Cu interface.     

Numerical and Experimental Investigations of Fracture Behaviour of Welded Joints with Multiple Defects

Current standards related to welded joint defects (EN ISO 5817) only consider individual cases (i.e., single defect in a welded joint). The question remains about the behaviour of a welded joint in the simultaneous presence of several different types of defects, so-called multiple defects, which is the topic of this research. The main focus is on defects most commonly encountered in practice, such as linear misalignments, undercuts, incomplete root penetration, and excess weld metal. The welding procedure used in this case was metal active gas welding, a common technique when it comes to welding low-alloy low-carbon steels, including those used for pressure equipment. Different combinations of these defects were deliberately made in welded plates and tested in a standard way on a tensile machine, along with numerical simulations using the finite element method (FEM), based on real geometries. The goal was to predict the behaviour in terms of stress concentrations caused by geometry and affected by multiple defects and material heterogeneity. Numerical and experimental results were in good agreement, but only after some modifications of numerical models. The obtained stress values in the models ranged from noticeably lower than the yield stress of the used materials to slightly higher than it, suggesting that some defect combinations resulted in plastic strain, whereas other models remained in the elastic area. The stress–strain diagram obtained for the first group (misalignment, undercut, and excess root penetration) shows significantly less plasticity. Its yield stress is very close to its ultimate tensile strength, which in turn is noticeably lower compared with the other three groups. This suggests that welded joints with misalignment and incomplete root penetration are indeed the weakest of the four groups either due to the combination of the present defects or perhaps because of an additional unseen internal defect. From the other three diagrams, it can be concluded that the test specimens show very similar behaviour with nearly identical ultimate tensile strengths and considerable plasticity. The diagrams shows the most prominent yielding, with an easily distinguishable difference between the elastic and plastic regions. The diagrams are the most similar, having the same strain of around 9% and with a less obvious yield stress limit.     

Dissimilar Laser Welding of Austenitic Stainless Steel and Abrasion-Resistant Steel: Microstructural Evolution and Mechanical Properties Enhanced by Post-Weld Heat Treatment

In this study, ultra-high-strength steels, namely, cold-hardened austenitic stainless steel AISI 301 and martensitic abrasion-resistant steel AR600, as base metals (BMs) were butt-welded using a disk laser to evaluate the microstructure, mechanical properties, and effect of post-weld heat treatment (PWHT) at 250 °C of the dissimilar joints. The welding processes were conducted at different energy inputs (EIs; 50–320 J/mm). The microstructural evolution of the fusion zones (FZ) in the welded joints was examined using electron backscattering diffraction (EBSD) and laser scanning confocal microscopy. The hardness profiles across the weldments and tensile properties of the as-welded joints and the corresponding PWHT joints were measured using a microhardness tester and universal material testing equipment. The EBSD results showed that the microstructures of the welded joints were relatively similar since the microstructure of the FZ was composed of a lath martensite matrix with a small fraction of austenite. The welded structure exhibited significantly higher microhardness at the lower EIs of 50 and 100 J/mm (640 HV). However, tempered martensite was promoted at the high EI of 320 J/mm, significantly reducing the hardness of the FZ to 520 HV. The mechanical tensile properties were considerably affected by the EI of the as-welded joints. Moreover, the PWHT enhanced the tensile properties by increasing the deformation capacity due to promoting the tempered martensite in the FZ.     

Modeling the Contact Interaction of a Pair of Antagonist Teeth through Individual Protective Mouthguards of Different Geometric Configuration

This study carried out modeling of the contact between a pair of antagonist teeth with/without individual mouthguards with different geometric configurations. Comparisons of the stress–strain state of teeth interacting through a multilayer mouthguard EVA and multilayer mouthguards with an A-silicon interlayer were performed. The influence of the intermediate layer geometry of A-silicone in a multilayer mouthguard with an A-silicon interlayer on the stress–strain state of the human dentition was considered. The teeth geometry was obtained by computed tomography data and patient dental impressions. The contact 2D problem had a constant thickness, frictional contact deformation, and large deformations in the mouthguard. The strain–stress analysis of the biomechanical model was performed by elastoplastic stress–strain theory. Four geometric configurations of the mouthguard were considered within a wide range of functional loads varied from 50 to 300 N. The stress–strain distributions in a teeth pair during contact interaction at different levels of the physiological loads were obtained. The dependences of the maximum level of stress intensity and the plastic deformation intensity were established, and the contact parameters near the occlusion zone were considered. It was found that when using a multilayer mouthguard with an A-silicone interlayer, there is a significant decrease in the stress intensity level in the hard tissues of the teeth, more than eight and four times for the teeth of the upper and lower teeth, respectively.     

Influence of Assembly Gap Size on the Structure and Properties of SUS301L Stainless Steel Laser Welded Lap Joint

The microstructure and properties of laser welding lap joints with different assembly gap sizes are experimentally investigated. The laser weld joint is composed of γ-austenite and δ-ferrite, and the strip ferrite phase is mainly distributed at the austenite grain boundary. The weld metal presents the austenitic-ferritic (AF) solidification mode. When there is a gap between the two plates, a triangular region composed of similar equiaxed crystals can be found, and the size of the cellular crystals in this region decreases significantly. When the assembly gap size increases from 0.1 mm to 0.4 mm, the weld penetration state of the joint changes from full penetration to semi-penetration, and the surface collapse increases. The excessive size of the gap leads to a decrease in the tensile-shear force and fatigue strength of laser welded joints. In order to ensure that the surface morphology and properties of the welded joint meet the quality standard and requirement, the assembly gap should be less than 0.1mm.     

Effective Range of FSSW Parameters for High Load-Carrying Capacity of Dissimilar Steel A283M-C/Brass CuZn40 Joints

In the current study, a 2 mm thick low-carbon steel sheet (A283M—Grade C) was joined with a brass sheet (CuZn40) of 1 mm thickness using friction stir spot welding (FSSW). Different welding parameters including rotational speeds of 1000, 1250, and 1500 rpm, and dwell times of 5, 10, 20, and 30 s were applied to explore the effective range of parameters to have FSSW joints with high load-carrying capacity. The joint quality of the friction stir spot-welded (FSSWed) dissimilar materials was evaluated via visual examination, tensile lap shear test, hardness test, and macro- and microstructural investigation using SEM. Moreover, EDS analysis was applied to examine the mixing at the interfaces of the dissimilar materials. Heat input calculation for the FSSW of steel–brass was found to be linearly proportional with the number of revolutions per spot joint, with maximum heat input obtained of 11 kJ at the number of revolutions of 500. The temperature measurement during FSSW showed agreement with the heat input dependence on the number of revolution. However, at the same revolutions of 500, it was found that the higher rotation speed of 1500 rpm resulted in higher temperature of 583 °C compared to 535 °C at rotation speed of 1000 rpm. This implies the significant effect for the rotation speed in the increase of temperature. The macro investigations of the friction stir spot-welded joints transverse sections showed sound joints at the different investigated parameters with significant joint ligament between the steel and brass. FSSW of steel/brass joints with a number of revolutions ranging between 250 to 500 revolutions per spot at appropriate tool speed range (1000–1500 rpm) produces joints with high load-carrying capacity from 4 kN to 7.5 kN. The hardness showed an increase in the carbon steel (lower sheet) with maximum of 248 HV and an increase of brass hardness at mixed interface between brass and steel with significant reduction in the stir zone hardness. Microstructural investigation of the joint zone showed mechanical mixing between steel and brass with the steel extruded from the lower sheet into the upper brass sheet.     

A Review: Laser Welding of Dissimilar Materials (Al/Fe,Al/Ti,Al/Cu)—Methods and Techniques,Microstructure and Properties

Modern structural engineering is impossible without the use of materials and structures with high strength and low specific weight. This work carries out a quantitative and qualitative analysis of articles for 2016–2021 on the topic of welding of dissimilar alloys. It is found that laser welding is most widely used for such metal pairs as Al/Fe, Al/Ti, and Al/Cu. The paper analyzes the influence of the basic techniques, methods, and means of laser welding of Al/Fe, Al/Ti, and Al/Cu on the mechanical properties and thickness of the intermetallic compound (IMC). When welding the lap joint or spike T-joint configuration of Al/Fe, it is preferable to melt the steel, which will be heated or melted, by the laser beam, and through thermal conduction, it will heat the aluminum. When welding the butt-welded joint of Al/Fe, the most preferable is to melt the aluminum by the laser beam (150–160 MPa). When welding the butt-welded joint of Al/Ti, it is possible to obtain the minimum IMC and maximum mechanical properties by offsetting the laser beam to aluminum. Whereas when the laser beam is offset to a titanium alloy, the mechanical properties are 40–50% lower than when the laser beam is offset to an aluminum alloy. When lap welding the Al/Cu joint, under the impact of the laser beam on the aluminum, using defocusing or wobbling (oscillation) of a laser beam, it is possible to increase the contact area of electrical conductivity with the tensile shear strength of 95–128 MPa.     

Influence of Welding Speeds on the Morphology,Mechanical Properties,and Microstructure of 2205 DSS Welded Joint by K-TIG Welding

In this paper, 8.0 mm thickness 2205 duplex stainless steel (DSS) workpieces were welded with a keyhole tungsten inert gas (K-TIG) welding system under different welding speeds. After welding, the morphologies of the welds under different welding speed conditions were compared and analyzed. The microstructure, two-phase ratio of austenite/ferrite, and grain boundary characteristics of the welded joints were studied, and the microhardness and tensile properties of the welded joints were tested. The results show that the welding speed has a significant effect on the weld morphology, the two-phase ratio, grain boundary misorientation angle (GBMA), and mechanical properties of the welded joint. When the welding speed increased from 280 mm/min to 340 mm/min, the austenite content and the two-phase ratio in the weld metal zone (WMZ) decreased. However, the ferrite content in the WMZ increased. The proportion of the Σ3 coincident site lattice grain boundary (CSLGB) decreased as the welding speed increased, which has no significant effect on the tensile strength of welded joints. The microhardness of the WMZ and the tensile strength of the welded joint gradually increased when the welding speed was 280–340 mm/min. The 2205 DSS K-TIG welded joints have good plasticity.     

Microstructural Characterization and Mechanical Properties of Laser Beam-Welded Dissimilar Joints between A6000 Aluminum Alloy and Galvanized Steel

This paper presents the laser beam welding process of a lap joint between galvanized steel (Z225) and an aluminum alloy (A6000) from an IPG fiber laser. Welding of steel to aluminum has become popular in the automotive industry as a means of reducing the total vehicle body mass. This approach reduces fuel consumption and, ultimately, carbon emissions. Laser welding parameters used to control heat input for the study were laser power ranging between 800 and 1200 W, as well as laser welding speeds between 2 and 4 m/min. Distinct features of the dissimilar joints were microscopically examined. The SEM-EDS technique was employed to study the intermetallic phases along the Fe-Al interface. The outcome revealed the presence of “needle-like phases” and “island-shaped phases” at high heat inputs. Traces of both Fe₂Al₅ and FeAl₃ phases were detected. For low heat input, there was evidence of insufficient fusion. Weld width was influenced by welding parameters and increased with an increase in heat input. Mechanical properties of the joints indicated that the microhardness values of the weld joints were higher than those of both base metals. The maximum tensile shear strength obtained was 1.79 kN for a sample produced at 1200 W and 3 m/min.     

The Uniaxial Stress–Strain Relationship of Hyperelastic Material Models of Rubber Cracks in the Platens of Papermaking Machines Based on Nonlinear Strain and Stress Measurements with the Finite Element Method

Finite element analysis is extensively used in the design of rubber products. Rubber products can suffer from large amounts of distortion under working conditions as they are nonlinearly elastic, isotropic, and incompressible materials. Working conditions can vary over a large distortion range, and relate directly to different distortion modes. Hyperelastic material models can describe the observed material behaviour. The goal of this investigation was to understand the stress and relegation fields around the tips of cracks in nearly incompressible, isotropic, hyperelastic accouterments, to directly reveal the uniaxial stress–strain relationship of hyperelastic soft accouterments. Numerical and factual trials showed that measurements of the stress–strain relationship could duly estimate values of nonlinear strain and stress for the neo-Hookean, Yeoh, and Arruda–Boyce hyperelastic material models. Numerical models were constructed using the finite element method. It was found that results concerning strains of 0–20% yielded curvatures that were nearly identical for both the neo-Hookean, and Arruda–Boyce models. We could also see that from the beginning of the test (0–5% strain), the curves produced from our experimental results, alongside those of the neo-Hookean and Arruda–Boyce models were identical. However, the experiment’s curves, alongside those of the Yeoh model, converged at a certain point (30% strain for Pieces No. 1 and 2, and 32% for Piece No. 3). The results showed that these finite element simulations were qualitatively in agreement with the actual experiments. We could also see that the Yeoh models performed better than the neo-Hookean model, and that the neo-Hookean model performed better than the Arruda–Boyce model.     

Mechanical Properties of Compact Bone Defined by the Stress-Strain Curve Measured Using Uniaxial Tensile Test: A Concise Review and Practical Guide

Mechanical properties are crucial parameters for scaffold design for bone tissue engineering; therefore, it is important to understand the definitions of the mechanical properties of bones and relevant analysis methods, such that tissue engineers can use this information to properly design the mechanical properties of scaffolds for bone tissue engineering. The main purpose of this article is to provide a review and practical guide to understand and analyze the mechanical properties of compact bone that can be defined and extracted from the stress–strain curve measured using uniaxial tensile test until failure. The typical stress–strain curve of compact bone measured using uniaxial tensile test until failure is a bilinear, monotonically increasing curve. The associated mechanical properties can be obtained by analyzing this bilinear stress–strain curve. In this article, a computer programming code for analyzing the bilinear stress–strain curve of compact bone for quantifying the associated mechanical properties is provided, such that the readers can use this computer code to perform the analysis directly. In addition to being applied to compact bone, the information provided by this article can also be applied to quantify the mechanical properties of any material having a bilinear stress–strain curve, such as a whole bone, some metals and biomaterials. The information provided by this article can be applied by tissue engineers, such that they can have a reference to properly design the mechanical properties of scaffolds for bone tissue engineering. The information can also be applied by researchers in biomechanics and orthopedics to compare the mechanical properties of bones in different physiological or pathological conditions.     

Interface Characteristics and Mechanical Properties of Ultrasonic-Assisted Friction Stir Lap Welded 7075-T6 Aluminium Alloy

In this work, friction stir lap welding (FSLW) and ultrasonic-assisted friction stir lap welding (UAFSLW) was applied to 6-mm-thick 7075-T6 alloy sheets using three welding tools with the same process parameters. The joint formation, microstructural characteristics, and mechanical properties of the resulting lap joints were then investigated. The results showed that ultrasonic vibration significantly promoted the flow of metal at the interface, enlarged the size of the stirred zone (SZ), and reduced the angle between the hook defect and the interface. During lap shear testing, the FSLW and UAFSLW joints fractured in a similar manner. The fracture modes included tensile fracture, shear fracture, and a mixture of both. Cold lap and hook defects may have served as crack-initiation zones within the joint. Under configuration A (i.e., upper sheet on the retreating side (RS)), all joints failed in the shear-fracture mode. The effective lap width (ELW) of the joint welded using tool T2 was the greatest. This resulted in a higher shear fracture strength. The maximum shear fracture strength of the UAFSLW joint was 663.1 N/mm. Under configuration B (i.e., upper sheet on the advancing side (AS)), the shear fracture strength was greatly affected by the fracture mode. The highest shear fracture strength of the UAFSLW joint, 543.7 N/mm, was welded by tool T3. Thus, under otherwise identical conditions, UAFSLW joints can withstand a greater fracture shear strength than FSLW joints, as ultrasonic vibration helps to mix the material at the interface, thus, enlarging the SZ and diminishing the cold lap defects.     

Mechanical Properties and Constitutive Model Applied to the High-Speed Impact of Aluminum Foam That Considers Its Meso-Structural Parameters

In this work, quasistatic mechanical compression experiments were used to study the stress–strain relationship of aluminum foam, and the mechanism of the compressive deformation of aluminum foam under quasistatic compression conditions is discussed based on the experimental observations. Since the interactions among cells of the aluminum foam and differences in compressive strength among cells substantially impacted the mechanical properties of the material, the cellular structural parameters, namely the cell size and cell wall thickness, were defined. Along with the mechanism of deformation of a single cell, the influence of structural parameters on the micro failure mechanism and the stress–strain relationship of the aluminum foam material was analyzed. In combination with the factors influencing the mechanical properties of the aluminum foam, a mechanical constitutive model of aluminum foam suitable for multi-density and multi-impact environments that considers cellular structure density was established to predict the complete stress–strain relationship of aluminum foam under a high strain rate. The coupling function of strain rate and temperature in the original model was verified and the parameters were determined by the compression experiments under different strain rates and different temperatures.     

Influence of Different Welding Parameters on the Morphology,Microstructure, and Mechanical Properties of 780 Duplex-Phase Steel Laser Lap Welded Joint

This paper attempted to establish a relationship between the morphology, microstructure and mechanical properties of a laser lap welded joint (WJ) of 780 duplex-phase (DP) steel under different welding parameters. The experimental results showed that the microstructure of the heat-affected zone (HAZ) of all the WJs were tempered martensite and equiaxed ferrite. The microstructure at the fusion zone (FZ) in all the WJs was dominated by lath martensite and ferrite, and the grain size of the FZ was larger than that in the base materials (BMs). The mechanical properties of the welded joints were tested by a universal testing machine, and the changing law of lap tensile resistance with the laser-welding parameters was analyzed. The results show that there was a linear relationship between the width of the weld and the tensile-shear forces of the weld, and the penetration of the weld had no obvious effect on the tensile-shear forces of the weld. A binary linear-regression equation was established to reveal the degree of influence of welding speed and laser power on the mechanical properties of WJs. It was found that the laser power had a greater influence on the mechanical properties of WJs than the welding speed.     

Study on Mg/Al Weld Seam Based on Zn–Mg–Al Ternary Alloy

Based on the idea of alloying welding seams, a series of Zn–xAl filler metals was calculated and designed for joining Mg/Al dissimilar metals by gas tungsten arc (GTA) welding. An infrared thermography system was used to measure the temperature of the welding pool during the welding process to investigate the solidification process. It was found that the mechanical properties of the welded joints were improved with the increasing of the Al content in the Zn–xAl filler metals, and when Zn–30Al was used as the filler metal, the ultimate tensile strength could reach a maximum of 120 MPa. The reason for the average tensile strength of the joint increasing was that the weak zone of the joint using Zn–30Al filler metal was generated primarily by α-Al instead of MgZn_2. When Zn–40Al was used as the filler metal, a new transition zone, about 20 μm-wide, appeared in the edge of the fusion zone near the Mg base metal. Due to the transition zones consisting of MgZn₂- and Al-based solid solution, the mechanical property of the joints was deteriorated.     

Microstructure and Interfacial Reactions of Resistance Brazed Lap Joints between TC4 Titanium Alloy and 304 Stainless Steel Using Metal Powder Interlayers

In the brazing joint between titanium alloy and stainless steel, a lot of Fe-Ti intermetallic compounds (IMCs) can be easily formed to make joints crack. A lap resistance brazing process with metal powder layers on both sides of the filler metal was used to solve this problem. The microstructure and metallurgical behavior of joints was studied through comparative experiments. The result showed that Nb, V and Cr powders and the solder reacted with the base material to form a new phase, which replaced the Ti-Fe brittle phase in the joint. At the same time, metal powder clusters hindered the diffusion of Ti and Fe elements and improved the distribution of new phases. The established atomic reaction model revealed the metallurgical behavior and formation mechanism of the joints. Therefore, the intervening position of the metal powder layer and the multi-reaction zone structure are the main reasons the shear strength of joints is improved.