Browse Topic: Welding

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Temperature Distribution and Effects of Heat-Affected Zone on the Mechanical Microstructure and Properties of Steel Pipes during Cutting2026-99-01257/31/2026
This paper examines the temperature distribution during pipe cutting and the impact of the heat-affected zone on the mechanical microstructure and properties of steel pipes. Utilizing testing equipment such as K-type thermocouples, a MESTL-WELD thermocouple spot welding machine, and a DC5516H 16-channel temperature data logger, temperature tests were conducted on Φ 1016 × 17.5 mm X70M spiral seam submerged arc welded steel pipes and Φ 1016 × 21 mm X70M straight-seam submerged arc welded steel pipes. The results indicate that the maximum test temperatures during cutting were 953.8 °C and 1216.6 °C, respectively, with the duration of temperatures exceeding 400 °C at each test point not exceeding 30 seconds. By fitting the relationship curve between the peak temperatures of each test point and the cutting distance using the ExpDec3 model, it was found that the cutting distance corresponding to a temperature of 580 °C was 12 mm. Furthermore, mechanical microstructure and property tests were performed on the pipe body at different positions of the HAZ. Except for an anomaly in the yield strength of the rod-shaped tensile specimens of the Φ 1016 × 21 mm X70M welded pipe body, no other abnormalities were detected. Macroscopic metallographic examination revealed that the axial length of the HAZ at the end of the cut pipe did not exceed 7 mm. Microhardness testing showed significant fluctuations in the microhardness of the pipe body at the end of the cut pipe, while the microhardness of the pipe body beyond 10 mm from the end gradually returned to normal.
Xu, Yan, Bai, Qiang, Feng, Zhenjun, Chang, Yonggang, Li, Liang, Peng, Shibi
Researching on Small Deformation Control Technology of Large Vertical Vacuum Vessels2026-99-01767/31/2026
This paper investigated the small deformation control of a large vertical vacuum vessel, a critical component in aerospace testing with stringent deformation limits under specific test conditions. Building on engineering experience and economic considerations, we designed oversized and multi-array external reinforcement rings tailored to the vessel’s spatial geometry to enhance its stiffness and stability. A novel integrated structural design was proposed, which mechanically couples the vacuum vessel with the concrete foundation via embedded components, specifically, by configuring optimized embedded parts at the vessel’s base and external reinforcement ring bottom, and then welding and binding these parts to the foundation’s embedded elements. This design significantly boosted the vertical vessel’s overall structural strength, rigidity, and stability. Ansys Workbench was used to simulate and analyze the vacuum vessel under different experimental conditions, and finite element simulations of the vessel under diverse experimental conditions validated that the integrated design achieves low stress and minimal deformation, compliant with test requirements. Post-installation deformation measurements further confirmed good agreement between experimental data and simulation results, verifying the model’s accuracy. The proposed fixed support structure addresses the limitations of traditional support systems for small-deformation applications and offers a new design paradigm for vertical vessel supports in high-precision engineering scenarios.
Bo, Yang, Shizeng, Lv, Xiao, Hao, Jie, Gong
Microstructure and Mechanical Properties of Vacuum Laser Welded Joints in 42CrMo Thick Plate2026-99-01327/31/2026
Vacuum laser welding trials were carried out on 42CrMo steel, a material widely utilized in the defense sector. By employing a 30 kW fiber laser system, complete penetration welds were successfully produced on 20 mm thick 42CrMo steel plates. The resulting joints displayed satisfactory surface quality on both the top and bottom sides, with no evident defects such as cracks or porosity. A comprehensive analysis of the joint microstructure and mechanical properties was conducted. Findings reveal that the weld zone (WZ) is predominantly composed of lath martensite, accompanied by minor quantities of plate martensite, organized as columnar crystals. The joints demonstrated high tensile strength at ambient temperature, with fracture consistently occurring within the base metal (BM). Microhardness measurements indicated higher values within the weld relative to the base metal, and no pronounced softening was detected in the heat-affected zone (HAZ). Additionally, the joints exhibited commendable impact toughness, suggesting overall superior mechanical performance.
Shi, Haicheng, Zhang, Guoyu, Li, Wuhong, Cao, Dongxu, Liu, Tianlei
Measurement and Regulation of Residual Stress in Door Opening Welds of Wind Turbine Towers2026-99-01977/31/2026
Weld residual stress is a critical factor affecting the structural integrity and service life of wind turbine towers. In this study, a systematic investigation was conducted on the residual stress distribution and control methods for door corner welds of an in-service wind turbine tower after approximately 20,000 hours of operation. X-ray diffraction (XRD) measurements revealed significant tensile residual stress in the weld and heat-affected zone, with peak values reaching 315 MPa, particularly concentrated at depths of 5-7 mm. To mitigate these stresses, two post-weld treatment methods were employed: ultrasonic impact treatment (UIT) and localized heat treatment. UIT effectively transformed surface tensile stress into compressive stress, achieving a maximum compressive residual stress of -372 MPa within a depth of 3 mm, while simultaneously refining grains and increasing surface hardness. In contrast, localized heat treatment at 460 °C for 5 hours led to a broader stress relief effect, reducing residual stress by approximately 100 MPa without causing significant changes to the macrostructure, but inducing substructural rearrangements beneficial for stress relaxation. Mechanical testing confirmed that both treatments improved tensile strength, ductility, and toughness of the welds. The combined findings demonstrate that ultrasonic impact treatment is highly effective for enhancing fatigue performance at the surface, while localized heat treatment offers advantages for deep stress redistribution and long-term structural stability. This comprehensive approach provides valuable technical guidance for residual stress management in complex welded structures of wind turbine towers.
Sun, Wanting, Zhong, Zhenqian, Zhang, Bo, Liu, Hui
Ultrasonic Assisted Room Temperature Welding of Liquid Gallium Indium Alloy Brazing Material and Its Solidification Behavior at the Cu-Cu Interface2026-99-01967/31/2026
Considerable the gallium-based alloys low melting point coupled with easy to synthesize intermetallic compounds with diverse metallic elements, employing liquid gallium-based alloys as the soldering medium and leveraging ultrasonic as assistance are effective to construct pure copper joints under atmosphere condition. The investigation delves into the characterization of the reaction products, interface microstructure, elemental distribution patterns, and evolution of shear strength within the welds. Furthermore, the pivotal role of ultrasonic waves and constituent element diffusion mechanisms during the solidification phase is elucidated. Thus, the initial one-day occurred during solidification showed the 2.6 MPa shear strength but with the time increased to four and a half days, the shear strength raised to 8.4 MPa at room temperature. Thereinto, the results indicate the weld seam has achieved metallurgical connection. This innovative welding technique operates at room temperature provides significant guidance for designing a novel perspective low-temperature joining for applications. It is not only augments the repertoire of material connection methodologies but also presents a viable joining strategy for sensitive elevated temperature materials. Therefore, such process possesses substantial practical significance and promises avenues for future applications.
Guo, Manying, Qu, Yingying, Fang, Qiuyue, Yang, Shen
Weld Formation, Microstructure, and Mechanical Properties of High-Speed Friction Stir-Welded 6061-T6 Aluminum Alloys2026-99-01267/31/2026
In this paper, 6061-T6 aluminum alloys were subjected to high-speed friction stir welding. The associated weld formation, microstructure, and mechanical properties were systematically examined via combined experimental observation and numerical simulation approaches. At a welding speed of 3000 mm/min and a rotation rate of 3800 rpm, the defect-free weld was simply achieved due to the simultaneous intense thermal input and enhanced material flow. Microstructural analysis further demonstrated a fine equiaxed grain structure featuring a predominant simple shear texture with A/A components. The resultant joint exhibited an ultimate tensile strength equivalent to 80% of the base material, accompanied by excellent fracture elongation. This research provides experimental evidence for designing high-efficiency and high-quality bonding processes for aluminum alloys.
Guan, Yuankai, Wang, Ruiyang, Zhang, Kexin, Lin, Zhicheng, Deng, Jun, Liu, Zhe, Ganushchak, Oleg, Voitenko, Oleksandr, Zhao, Yunqiang, Gao, Shiyi
Research on Welding Deformation of the Car Body Based on 3D Laser Scanning2026-99-08217/30/2026
This study aims to verify the accuracy and stability of a system used for measuring and analyzing the welding deformation of vehicle bodies under different welding parameters. A 3D laser scanner was employed to capture the surface topography data of the vehicle’s front deck before and after welding. In order to determine the welding deformation, PolyWorks software was utilized for deformation analysis, which processed the 3D scanning data and compared the post-welding data set. A dedicated vehicle body welding deformation measurement system was developed, including hardware configuration and software development. The BP neural network algorithm was adopted to predict the welding deformation, and the results indicated that the deviation between the predicted values and the average experimental measurements was less than 10%. This confirmed the practicality of the BP neural network in predicting welding deformation and highlighted its effectiveness in technical support for the optimization of welding parameters and deformation control in automotive manufacturing.
Li, Lina, Zhang, Yiqi, Sun, Hongchang, Wei, Xiezhen
Three-Dimensional Transient Thermal-Fluid Coupling Numerical Simulation of the Molten Pool in Aluminum Alloy Laser Welding2026-99-08547/30/2026
Laser welding technology for aluminum alloy electrode and busbar connections: addressing challenges in battery module assembly. In this work, a CFD framework was built in ANSYS Fluent using a Gaussian rotating heat-source representation, while a VOF approach was used to capture the transient gas–liquid interface in deep-penetration welding. A three-dimensional, transient, thermal-fluid coupled numerical model of the dual-layer heterogeneous aluminum alloy laser deep penetration weld pool was established concurrently with laser deep penetration welding experiments. Results indicate: Peak flow velocities in the weld pool during welding are concentrated along the weld centerline, with flow vectors predominantly directed axially along the weld. Once a quasi-steady keyhole regime is established, vaporization-induced recoil pressure becomes the primary driver governing melt circulation. The liquid metal first impinges on the pool bottom along the keyhole wall and then recirculates upward near the pool boundary, producing strong vortical motion. These findings are intended to support parameter selection and process optimization for laser welding of layered dissimilar aluminum components used in battery tab–busbar assemblies.
Lv, Wenjun, Wu, Yan
Research on the Hysteresis Performance of Welded Hollow Spherical Joints under Low Temperature2026-99-16417/24/2026
The extreme cold environment has a significant impact on the mechanical properties of welded hollow ball nodes, which are crucial components in large-span steel structures. In this paper, based on the comprehensive test data of drum-shaped welded hollow sphere nodes from Beijing Daxing International Airport, a sophisticated finite element model incorporating welding residual stress is established. Through detailed static loading analysis and systematic hysteresis performance studies, the research thoroughly explores the influence mechanisms of low temperature on node bearing capacity, deformation capability, and energy dissipation performance. The investigation reveals that while the bearing capacity of the nodes increases significantly in low-temperature environments, both their plastic deformation capacity and energy consumption performance are notably reduced. These findings provide valuable theoretical references for the design and optimization of large-span mesh frame structures in cold regions, enabling engineers to better account for temperature effects in structural calculations and safety assessments. The results have important implications for improving the reliability and durability of steel structures in extreme cold environments.
Luo, Yanzhi, Jin, Changming
Research on the Microstructure and Properties of X80 Steel Circumferential Welds Under Different Automatic Welding Processes2026-99-16367/24/2026
Two sets of X80 pipes with a diameter of 1219 mm × 27.5 mm were welded using a fully automatic welding process (GMAW) and a combined automatic welding process (GTAW + FCAW-G), respectively. By analyzing the microstructure, strength, impact toughness, and fracture toughness of welded joints, the differences in microstructure and properties of circumferential weld joints under different automatic welding processes were studied. The results showed that the design of multi-layer and multi-pass welding and appropriate heat input controlled the microstructure of the weld seam and heat-affected zone area of the circumferential weld joint. Both automatic welding processes obtained welded joints with finer microstructure, thereby ensuring the strength and toughness of the joint. The tensile strength and yield strength of the welded joints under two automatic welding processes reach over 680 MPa and 600 MPa, respectively. The welded joints under both automatic welding processes have good impact toughness and fracture toughness at - 10 °C, with a ductile-brittle transition temperature below -50 °C and crack tip opening displacement (CTOD) values greater than 0.254 mm. The tensile strength, yield strength, impact toughness, and fracture toughness of the fully automatic welding ring weld joint are better than those of the combined automatic welding.
Liu, Jian, Niu, Huli, Wang, Hong, Sun, Xinyan, Yang, Huaqing, Bai, Qian
A Review of Welding Techniques in Metal Additive Manufacturing: Advancements, Challenges, and Future Directions05-19-04-00296/10/2026
The present review evaluates recent advances in the development of Welding-Based Additive Manufacturing (WBAM) technologies using arc, high-energy density, solid-state, and hybrid welding systems by providing an interdisciplinary assessment of technological aspects, sensing, process optimization, and multi-process strategies. It is concluded that, in spite of considerable progress in process optimization and control, there exist numerous paradoxes associated with relationships among process conditions, structure, and properties, especially those related to heat input effects on material microstructure and performance. An important finding is the fragmentation of predictive modeling approaches, where physics-based and data-driven methods remain inadequately integrated, limiting generalizability and accuracy. Another important conclusion is related to the dominance of the effect of thermal history and multi-physical phenomena on the mechanical performance of the material produced by WBAM technologies. Besides, the complexity and contradiction in defect generation mechanisms, monitoring, and evaluation methodologies restrict the development of process standardization and certification. New directions in intelligent fabrication based on artificial intelligence and digital twins are identified.
Santhana Babu, A.V., John Rajan, A., Mishra, Aishwary, Chakravarthy, P., Jayabalakrishnan, D.
Evaluation of Mechanical Tensile Properties on TIG-Welded AISI 304L Austenitic Stainless Steel Using Principal Component Analysis05-19-04-00275/14/2026
The reliability of welded joints is a vital factor in modern manufacturing, directly affecting product performance and durability. This study investigates methods to enhance the mechanical and metallurgical quality of butt joints in AISI 304L stainless steel welded by the gas tungsten arc (GTA) process. A systematic experimental design was implemented using the Taguchi method with an L9 orthogonal array, considering welding current, gas flow rate, and travel speed as the main parameters. To determine overall weld performance, the joints were characterized by measuring ultimate tensile strength (UTS), yield strength, percentage elongation, and examining their microstructural morphology. An experimental strategy based on the Taguchi approach has been implemented. The welding performance of the material was investigated, and the process parameters were optimized using multiresponse optimization through principal component analysis (PCA), incorporating an orthogonal array design, signal-to-noise (S/N) ratio, and analysis of variance (ANOVA). C1G1S3—the predicted optimal parameter combination—is the ideal factor configuration as determined by PCA (welding current = 100 A, gas flow rate = 10 L/min, travel speed = 2 mm/sec). Results demonstrate that precise control of process parameters significantly enhances weld quality. The methodology also provides a systematic framework that engineers and practitioners can apply to produce reliable stainless steel welds with improved accuracy and predictability.
Ghosh, Nabendu, Roy, Angshuman
Multiphysics Modeling and Performance Assessment of Ultrasonic Welding for Thermoplastic CompositesF-0082-2026-01205/5/2026
Ultrasonic welding (UW) provides a rapid and efficient method for joining composite components by inducing resin flow through thermally driven diffusion and crystallization at the bonded interface. However, in the absence of a multiphysics modeling framework or a digital twin approach, current practice still depends on extensive trial-and-error testing to determine key welding parameters such as vibration amplitude, weld time, weld pressure, hold time, and downspeed. While in-situ thermal cameras can monitor surface temperatures, the internal temperature at the bonded interface is often significantly higher, introducing the risk of thermal degradation and inconsistent bond quality. To overcome these limitations, GEM developed a high-fidelity multiphysics model to establish a quantitative relationship between process parameters and the evolving temperature field within welded thermoplastic parts. The model integrates coupled mechanical, thermal, and acoustic physics to simulate high-frequency vibrations and static pressure, capture the generation and spatial distribution of heat, and represent the temperature-dependent viscoelastic response that governs bond formation. A validation test matrix was designed by systematically varying weld time and vibration amplitude. Through-thickness temperature distributions were measured using infrared thermal imaging, enabling direct comparison with model predictions. Upon validation, the model was applied for process tailoring, allowing precise control of temperature distribution to achieve target bond strength. This integrated modeling and validation approach demonstrated substantial benefits, including reduced design iterations, accelerated process optimization, and improved quality and performance of welded composite structures.
Walthers, Mark, Li, Rui, Wei, Qingxuan, Lua, Jim
Investigation of Metallurgical and Mechanical Behaviors of AA6061-AA2017 Joints Produced by Single- and Double-Pass Friction Stir Welding: Influence of Base Material Position and Post-Weld Shot Peening Technique05-19-04-00264/13/2026
The growing demand for lightweight, high-strength materials in marine and aerospace structures has promoted the use of friction stir welding (FSW) for welding dissimilar aluminum alloys. However, tensile residual stresses and microstructural heterogeneities often degrade weld integrity. This study investigates the combined impact of base material positioning, single- and double-pass FSW, and post-weld shot peening (SP) on the metallurgical and mechanical properties of AA6061–AA2017 joints. Five welding configurations were examined to evaluate how varying base material positions on the advancing and retreating sides affect material flow and mechanical behavior. Post-weld SP effectively presented compressive residual stresses, reduced surface defects, and refined surface grains. The average grain size in the stir zone was reduced from 5.2 μm (single-pass) to 2.0 μm (double-pass U-turn) after SP, confirming significant grain refinement through dynamic recrystallization. Mechanical testing revealed that double-pass FSW with opposite weld direction (U-turn) followed by SP achieved the highest performance, with ultimate tensile strength (UTS) improving from 246 MPa to 289 MPa (≈17% increase) and tensile elongation rising from 8.78% to 9.41%. Microhardness in the heat-affected zone improved up to 127 VHN, countering thermal softening effects. The synergistic effect of double-pass welding and SP enhanced homogeneity, fatigue resistance, and surface integrity. The results establish SP as an efficient post-FSW treatment for dissimilar aluminum joints, offering quantifiable improvements in strength and ductility, making the process highly suitable for demanding marine and aerospace structural applications.
Nukathoti, Raja Sekhar, Battina, N. Malleswara Rao, Vanthala, Varaha Siva Prasad, Chirala, Hari Krishna, Maloth, Balu
Strain-Based Fracture Assessment of Tailor Welded Blanks under Complex Loading Conditions2026-01-02314/7/2026
Tailor Welded Blanks are critical for automotive lightweighting yet prone to premature failure due to differential thickness and strength across the weld. This study utilized digital image correlation (DIC) to analyze the maximum in-plane principal Hencky strain (E₁max) and axial strain (εₐₓₐₗ) of TWBs under complex loading conditions, including biaxial and plane-strain states. Twelve distinct material stack-ups were tested to evaluate the impact of material difference on formability. Results indicated that differential properties significantly altered strain distribution, often forcing localization onto the thinner or softer sheet. While UHSS welds provided high load capacity with limited ductility, combinations using HSLA or IF substrates were susceptible to early localization and unstable fracture. Comparative heatmaps illustrate strain evolution across all samples, providing spatial insights beyond conventional force–displacement analysis. Metallurgical characterization confirmed a strong correlation between failure behavior and microstructural features, specifically heat-affected zone softening and martensitic transformation. Notably, once the strength ratio exceeds 2.0, biaxial stretchability drops sharply and failure transitions from base-metal necking to weld-initiated cracking, indicating a severe mechanical mismatch effect. The observed hierarchy of critical strains (E₁ biaxial > E₁ plane-strain > E₁ uniaxial) confirms that biaxial testing represents the upper-bound deformability condition for these welded blanks. Collectively, these findings provide actionable guidance for optimizing TWB design in battery electric vehicle structures, where material heterogeneity and complex loadings are prevalent challenges.
Aminzadeh, Ahmad, Sheng, ZiQiang, Huang, Lu, McCarty, Eric, Biro, Elliot
Optimizing Joint Efficiency in Stainless Steel-Aluminum Alloy FSW Joints through Advanced Parameter Control2026-01-02284/7/2026
The present study investigates optimization of ultimate tensile strength (UTS) in FSW of AA2024-T3 and SS304 in a butt joint configuration. An L18 mixed-level orthogonal array was used to design 18 experiments, varying tool rotational speed (450, 560, and 710 rpm), traverse speed (20, 25, and 40 mm/min), and pin offset (1 and 1.5 mm toward the Al side). The tool rotational speed had the greatest influence on UTS, contributing nearly one-third of the total variance, followed by pin offset and traverse speed. The optimal combination, 450 rpm, 20 mm/min, 1.5 mm offset, yielded a UTS of 344.7 MPa and a joint efficiency of 78.3%. At this setting, peak temperatures reached ~356 °C, ensuring sufficient plasticization and uniform mixing of the Al–SS interface, producing a refined stir zone with an average grain size of 4.2 μm. Fracture analysis revealed ductile failure at the optimal parameters, whereas suboptimal conditions resulted in brittle or mixed fractures due to either insufficient or excessive heat input. These results demonstrate that Taguchi optimization effectively correlates process parameters, thermal profile, material mixing, and mechanical performance, enabling reliable, defect-free dissimilar FSW joints for structural and aerospace applications.
Mir, Fayaz Ahmad, Khan, Noor Zaman, Pali, Harveer Singh
Investigation on Microstructure and Mechanical Properties in the Dissimilar Joining of WE43 to AA7075 Alloy using FSW2026-01-02294/7/2026
This research investigates the alterations in microstructure, microhardness, and joint strength resulting from the dissimilar friction stir welding (FSW) of WE43 magnesium alloy to AA7075 aluminium alloy. The study specifically analyses the role of FSW process parameters in the formation of intermetallic compounds (IMCs), the evolution of grain structure, the resultant microhardness distribution across the weld zone, and the joint tensile strength. A comprehensive microstructural characterization was performed utilizing optical microscopy (OM), field emission scanning electron microscopy with energy-dispersive X-ray spectroscopy (FESEM-EDS), electron backscatter diffraction (EBSD), and X-ray diffraction (XRD). These analyses confirmed significant grain refinement in the stir zone and the identification of various IMCs at the weld interface. Microhardness mapping indicated a gradient profile, with the weld nugget exhibiting superior hardness attributed to its dynamically recrystallized, fine-grained microstructure. Crucially, the low-heat-input FSW (LFSW) variant yielded a substantial increase in average microhardness, reaching 126 HV in the stir zone (SZ), due to grain refinement induced by severe plastic deformation. This configuration achieved a joint efficiency of approximately 68.7% relative to the WE43 base material. The enhancement in mechanical performance is directly linked to a modified joint preparation strategy that successfully suppressed the formation of brittle AlMg IMCs, instead fostering the formation of harder MgZn, Al2CuMg, and AlMgZn compounds. These findings underscore the efficacy of the LFSW technique in fabricating dissimilar WE43-AA7075 joints with favourable mechanical properties and a consistent microhardness profile. The process parameters are strategically selected to achieve better joint properties and form defect-free joints.
Ahmad, Tariq, Khan, Noor Zaman, Ahmad, Babar, Siddiquee, Arshad Noor
Optimizing Weld Placement in Automotive Structures Using Topology and Multi-Disciplinary Approaches2026-01-05144/7/2026
This work presents two approaches for weld optimization aimed at reducing manufacturing cost and process time, while meeting structural performance requirements in automotive structures. The first approach uses topology optimization to identify the most efficient weld layouts. A design space is generated along mating flanges, joints, and panel interfaces, where potential weld locations are defined. Welds are treated as discrete design variables, and the topology optimization systematically evaluates their contribution to global stiffness and load path integrity. Non-critical welds, those with minimal impact on stiffness, durability, or crashworthiness, are eliminated, resulting in a minimized weld pattern that maintains structural performance. The second approach applies Multi-Disciplinary Optimization (MDO) to balance weld reduction with performance targets across multiple domains, including linear and non-linear stiffness, crashworthiness, and fatigue. Using a preprocessing tool, welds are parameterized to allow flexible control of their placement. A Design of Experiments (DoE) is generated to simulate various weld configurations under relevant load cases. Surrogate models are then developed to approximate the relationship between weld layout and key performance metrics. These response surfaces enable efficient optimization that minimizes weld count while satisfying all structural requirements. Together, these strategies form a data-driven, simulation-based framework for weld design that supports aggressive cost and time reduction targets without compromising safety or durability. The results demonstrate the potential for integrating advanced optimization techniques into early design phases for more efficient and manufacturable vehicle structures.
Koppaka, Vinaya, Yoo, Dong Yeon, Chavare, Sudeep
Conjugate Heat Transfer Modeling for Predicting Thermal Behavior of X76 Emotor Windings2026-01-01184/7/2026
A computational study based on a conjugate heat transfer (CHT) method in SimericsMP+ was performed to predict the winding temperatures in an X76 emotor. In this study, the thermal load was represented in the simulation through the solution of electromagnetic equations in SimericsMP+, where heat generation was driven by root-mean-square (RMS) current, while liquid cooling was applied at flow rates ranging from 1 LPM to 6 LPM. Simulations were conducted to measure the temperature on three thermocouple locations on each side of the winding crown and weld regions under steady operation. The computational strategy employed a loosely coupled approach. A fluid-only simulation was first carried out to establish stable flow conditions, followed by coupling with solid conduction where the winding acted as the heat source. The predicted temperature distributions were then compared with test data. Results obtained show good agreement, with differences remaining within an acceptable range, thereby confirming the accuracy of the numerical method. Findings demonstrate that the CHT approach not only reproduces measured winding temperatures but also provides detailed insight into local flow and temperature fields inside the emotor, information not accessible through physical testing alone. The validated methodology offers a reliable tool for guiding thermal management design and optimization of electric machines under varying cooling conditions.
Jia, Kun, Schlautman, Jeff, Srinivasan, Chiranth
A Novel Spot Joint Finite Element for Rapid Stress Analysis of Fasteners in Automotive Structures2026-01-01824/7/2026
Due to the spot weld and mechanical fastener share the similar characteristics to join sheets together with differences in deformation behavior around joint region, a novel spot joint element (user-defined element) consists of regular Mindlin shell elements and equations for different kinematic constraints is proposed to simplify the spot joint representation in lightweight automotive structures. The novel spot joint element can not only provide accurate deformation behavior around joint region but also output mesh-insensitive structural stresses at virtual nodes with the use of traction-based structural stress method for fatigue failure analysis. In this investigation, the structural stress distributions around joint circumference in the lap-shear specimens with spot weld or fastener are first calculated to validate the accuracy of the novel spot joint element. Then, the structural stresses along different cross-sections emanating from joint are also calculated for the specimens with fasteners to investigate the potential different failure modes. Finally, the fatigue data correlation based on the novel spot joint element and traction-based structural stress method using available literature data are presented and served as example applications.
Wu, Shengjia, Zhang, Lunyu, Dong, Pingsha
Integrated Welding Simulation and Experimental Characterization of Weld-Metal and Heat-Affected-Zone Strength in AA6063-T62026-01-02304/7/2026
In the context of automotive lightweighting and efficient manufacturing, welding is a key joining method for aluminum body structures due to its maturity, versatility, and cost effectiveness. This study investigates MIG butt welding of AA6063-T6 sheets using a sequential thermo-mechanical finite element model with a double-ellipsoid heat source. Thermocouple histories and macroscopic metallography of the weld-pool morphology are used to validate the predicted temperature field, and post-weld deformation measured by a coordinate measuring machine is compared with the simulation to confirm overall model reliability. Hardness mapping across the joint partitions the material into weld metal (WM), heat-affected zone (HAZ), and base metal (BM). Miniature tensile specimens extracted along the weld provide local mechanical properties, from which linear strength–hardness relations are established. Building on these results, a five-material equivalent strength model covering WM, HAZ-I, HAZ-II, HAZ-III, and BM is formulated to enable region-wise elastoplastic parameter assignment. The model reproduces the load–displacement response of transverse joint tests and accurately identifies necking in HAZ-II. An integrated workflow that combines simulation, measurement, property characterization, and modeling provides robust support for weld-strength assessment and process optimization in aluminum body structures.
Shao, Jiyong, Meng, Dejian, Xiang, Yao, Gao, Yunkai
A Study on Fatigue Life Prediction Method for Point-Based Joints Considering Multiple Fracture Modes – FDS, Blind Rivet, and Blind Nut Focus2026-01-01804/7/2026
The application of multiple materials in vehicle bodies is accelerating as the adoption of lightweight aluminum alloys and composite materials advances rapidly. These materials play a crucial role in reducing overall vehicle weight, enhancing fuel efficiency, and complying with increasingly strict environmental regulations. As the automotive industry continues to evolve toward electrification and sustainability, the integration of lightweight and high-performance materials has become a key design strategy. However, the use of multiple materials creates new challenges in manufacturing, particularly for joining technologies. Since different materials have varying mechanical properties, thermal behavior, and surface characteristics, the selection of appropriate joining methods is essential for ensuring structural integrity and durability. Depending on material types, thicknesses, production processes, and cost constraints, various joining techniques—such as mechanical fastening, welding, and adhesive bonding—are selectively applied. This study focuses on fatigue life prediction for point-based joints commonly used in automotive structures, including flow drilling screws (FDS), blind rivets, and blind nuts. Fatigue fractures in these joints typically propagate in multiple directions: through the sheet thickness and along the in-plane direction. Accurate fatigue life prediction requires numerical simulations that account for both crack propagation paths and the interaction of these paths with joint geometry and loading conditions. Traditional fatigue models often assume a single fracture mode, limiting the ability of these models to evaluate multiple failure mechanisms simultaneously. To address this issue, this study proposes a simplified modeling approach that enables the simultaneous consideration of multiple fracture modes. This paper introduces a numerical analysis-based method capable of predicting the fatigue strength of point joints, and describes the fatigue tests that were conducted to validate the proposed approach. This research contributes to the development of more reliable and efficient design strategies for multi-material automotive structures.
Takuno, Sougo, Isono, Toshiyuki, Urakawa, Kazushi, Goto, Suguru, Kawamura, Hiroaki, Niisato, Eita, Ishigami, Yuta
EP40: Structural Epoxy Used for Steel Bonding in Marine Applications26AERP04_074/1/2026
Master Bond EP40 is a two-part, room temperature curing epoxy for bonding, sealing, coating, and encapsulating. EP40 bonds well to a variety of substrates, including naval steel, the primary structural metal used in the shipbuilding industry. Master Bond Inc., Hackensack, NJ To reduce its environmental impact and pollution, the shipping industry is investigating methods to construct more lightweight ships. One potential method is using adhesive bonding techniques to replace traditional welding and riveted joints on ships to fabricate lighter ships with smaller carbon footprints. However, adhesives age and deteriorate when exposed to moisture, high temperatures, and ultraviolet light. This makes it necessary to understand how they age in maritime environments to determine whether they can truly replace traditional welding techniques. To this end, researchers at Centro de Investigación en Tecnologías Navales e Industriales (CITENI) and Centro de Investigación TIC (CITIC) developed a new method for studying adhesive aging on naval steel substrates. Master Bond EP40 was selected as the test adhesive for this method due to its strong performance and suitability for marine conditions. By using EP40, the team ensured that the observed adhesive bonding behavior would reflect a high-quality epoxy's potential in ship structures. The goal was to evaluate how EP40 bonds to naval steel and how the bulk epoxy material would behave in seawater to provide insights into the construction of lighter ships using this approach.
On the Modal Characteristics of Motor Stators under Different Interlaminate Fastening Conditions14-15-01-00052/14/2026
The increasing demand for quiet and efficient electric vehicles has highlighted the importance of understanding vibration and noise characteristics of motor stators. Previous studies have extensively modeled electromagnetic excitation and laminated structures, but there has been little experimental evidence clarifying how different interlaminate fastening methods affect vibration modes under comparable conditions. This knowledge gap limits the ability to optimize fastening strategies for noise and vibration control in practical motor design. In this study, laminated stator cores were fabricated with different fastening conditions—bolting, clinching, and welding—and subjected to vibration testing and experimental modal analysis. Natural frequencies, damping ratios, and mode shapes were identified for torsional, circumferential, and breathing modes. The results revealed that the in-plane torsional natural frequencies increase with bolt axial force, while clinching provides additional resistance to interlaminate movement but shows only a minor dependence on the number of clinching points. In contrast, the circumferential modes and the breathing-type (0,0) mode remain largely unaffected by these fastening variations. Welding points did not exhibit a consistent trend across the tested conditions, indicating that their influence on the modal properties is less systematic compared with bolting and clinching. The findings contribute not only to fundamental understanding of laminated stack vibration behavior but also to practical guidelines for designing fastening strategies that enhance vibration robustness and acoustic performance in automotive electric motors.
Matsubara, Masami, Saito, Akira, Shimada, Shogo, Oishi, Taizan, Furuya, Kohei, Kawamura, Shozo, Tajiri, Daiki
Aerospace & Defense Technology: February 202626AERP022/5/2026
Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace Smarter Pyrovalve Alternatives for Modern Missile and Munition Launcher Applications Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight Model-Based Design Is Shaping the Next Phase of eVTOL Systems Development How RF-over-Fiber is Providing the Backbone of Next Generation Mil/Aero Networks NASA Demonstrates a First-of-Its-Kind Space Communications A Rainfield Simulator for Hypersonic Testing The U.S. Army Space and Missile Defense Command Technical Center's Aerophysics Research Facility, (ARF), fired a successful hypersonic shot to test its new rainfield simulator. Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research Auburn University's Applied Research Institute in Huntsville is adding some serious fiber to its diet. The Critical Impact Of SAE Aerospace Standards: Certified AS1895/7 and /23 Metal Seals How engineers can ensure safety, reliability and quality in aerospace systems.
Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight26AERP02_032/1/2026
Between the 1920s and 1930s, aluminum started replacing wood as the primary material in aircraft construction and soon became the backbone of modern aviation. Its popularity stemmed from a combination of properties, high strength-to-weight ratio, corrosion resistance, and ease of forming that made it ideal for demanding aerospace applications. Throughout much of the 20th century, high-strength aluminum alloys dominated aircraft design, accounting for 70-80 percent of commercial airframes and more than half of many military aircraft. Even after the introduction of fiber-polymer composites in the early 2000s, aluminum has remained a critical material because it continues to offer the strength, lightness, and versatility needed for modern aviation. Industry forecasts predict that commercial air travel will double in the next 25 years, which means more pollution will be released into the atmosphere. One way to help reduce these emissions is by building airplane fuselages and wings with lighter and stronger materials.
Study of Style Wheel Rim Failure Due to Rim and Disc Assembly Interference2026-26-05411/16/2026
This study focuses on the investigation of wheel rim failures near weld zone during repeated cornering induced by interference between the rim and disc during the wheel manufacturing assembly process. Strain gauges were employed to capture real-time stress and strain distributions at critical zones during interference fitting. The experimental results revealed that improper interference levels lead to significant stress concentrations, often surpassing the material's elastic limit, initiating micro-crack formation and promoting fatigue failure. Detailed strain analysis indicated that both radial and axial stresses contribute to long-term structural degradation. The study highlights the critical role of dimensional tolerances, surface finishes, and assembly forces in minimizing stress-induced failures. Recommendations are provided for optimizing design and assembly practices to enhance the durability and reliability of automotive wheels.
P, Praveen, DEsigan, Lakshmipathy, K, Chandramohan, C, Santhosh
Failure Analysis of Dissimilar Metal Weld Joint of an Air Spring Bracket within an Automotive Active Seat Suspension System2026-26-04871/16/2026
In modern four-wheelers, seat suspension systems play a crucial role in enhancing occupant comfort by mitigating the effects of road unevenness and vibrations. Among these systems, active suspension mechanisms offer advanced performance through complex assemblies involving welded, riveted, and bolted joints. This study investigates the failure of an air spring bracket - a critical component of a pneumatic active suspension system - manufactured by Gas Metal Arc Welding (GMAW) of two dissimilar ferrous materials which are likely to be SAPH440 and S355J2. These different materials were used based on mechanical properties required to perform by their particular part. System level validation tests were conducted to ensure the reliability of the seat suspension system. The one of the validation tests is continuous cyclic fatigue test which is carried out on the complete seat assembly. However, during vibration / cyclic endurance testing, premature failures were observed near the weld joints. Detailed failure analysis using Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), and optical microscopy revealed cracks and discontinuities at the weld interfaces. The microstructure in the heat-affected zone (HAZ) exhibited ferrite-Martensite structure with grain coarsening. The fractography reveals the cleavage type and river type fracture morphology which indicates the part failed due to brittle fracture. Inadequate welding of SAPH440 steel can lead to issues such as cracking, distortion, and poor fusion due to its high carbon content and inadequate heat control. The failure analysis study identified that less fusion control of welding parameters and associated thickness and carbon compositions variation which significantly contributed to the component’s fatigue failure. Preventive strategies, including the optimization of sectional thickness and design changes for uniform stress distribution are proposed to improve the reliability of welded assemblies.
Patale Jr, Reshma, Pinjari, Jayant Namdev, Bali, Shirish
Advancing Welding Excellence Through Numerical Simulation Based Approach: A Multi Pass Welding Case Study on Cast Iron Coupons2026-26-04571/16/2026
The Automotive industry widely uses cast iron due to its better mechanical performance and cost-effectiveness. However, repair welding or assembly of cast iron components remain highly challenging due to the material’s high carbon content, inherent brittleness, rapid thermal conductivity, and complex microstructural transformations. Multi-pass welding exacerbates these challenges by subjecting materials to repeated thermal cycling, accumulating residual stress, and inducing distortion – all of which potentially degrade the integrity of welded joints. A comprehensive understanding of welded joint behavior is essential to effectively mitigate these effects. Finite element analysis (FEA) serves as a powerful tool, enabling accurate prediction of thermal profiles, phase transformations, residual stress development, and resulting deformations. These valuable insights are critical for optimizing welding processes and enhancing overall joint quality. This study investigates and validates the use of FEA-based simulation tools for multi-pass MIG welding of ductile cast iron plates, highlighting the effectiveness of virtual modeling in complex welding scenarios. A numerical simulation of 20 mm thick cast iron plates welded with Ni-Fe filler wire was conducted using SYSWELD software. The distortion, temperature distribution, microstructure, hardness, and residual stresses of the weld coupon were predicted using a thermo-metallurgical-mechanical model. The simulation incorporated a double-elliptical heat source for welding and an imposed thermal cycle model for pre- and post-weld heat treatments. Metallurgical analysis was performed utilizing a phase transformation model and Continuous Cooling Transformation diagram to estimate microstructural phase fractions and hardness. The mechanical analysis, based on the thermo-metallurgical profile and boundary conditions, evaluated weld distortion and residual stresses on weld coupon. Predicted results, including thermal cycles, fusion zone, distortion, hardness, and residual stresses, were validated against experimental data showed strong coherence. This study demonstrates the efficacy of FEA tools in accurately predicting dissimilar weld properties, reinforcing their reliability for welding and repairing cast iron components in industrial applications.
Vidhate, Digambar, Nalawade, Rahul, Dabhadkar, Mandar, Vaidya, Abhijit, Ammasi, Vinoth, Rajagopalan, Sridhar
Numerical Investigation on Thermo-Mechanical Characteristics of Injection-Molded Thermoplastics using Anisotropic Material Properties2026-26-02801/16/2026
This paper presents a comprehensive numerical methodology for simulating the coupled process-structure behavior of short glass fiber-reinforced, injection-molded thermoplastics. The approach integrates elastoplastic and anisotropic material characteristics using three engineering tools: Moldflow, Digimat, and ABAQUS. It accounts for fiber orientation and injection molding defects, linking to thermo-mechanical performance. This method enables accurate virtual modeling of real-time injection-molded components by transferring anisotropic data from Moldflow to ABAQUS. In this study, short fiber orientation and potential injection molding defects such as weld lines and residual stresses are discussed using Moldflow simulation. Besides, Digimat is employed as an interface tool to facilitate the transfer of Moldflow simulation results, namely fiber orientation and material behavior in the allied configurations directly into ABAQUS. This integration enables the evaluation of thermo-mechanical behavior in injection-molded thermoplastic components, incorporating material anisotropy. The simulation results demonstrate that anisotropic modeling effectively captures the influence of short fiber orientations, revealing localized stress distributions and macroscopic failure indicator results. Outcomes of the current approach are compared with isotropic simulations that exclude injection molding data, highlighting the advantages of incorporating process-induced anisotropy. These findings enhance understanding of the mechanical performance of short fiber-reinforced thermoplastics and provide a foundation for future integration of multi-scale finite element tools. The application of this methodology supports the development of cost-effective and efficient virtual product designs by accurately predicting deformation and failure under various loading conditions.
T, Kalinga, Yanamadala, Dharma Teja, Mattupalli, Venkata, Chirravuri, Bhaskara, Miller, Ronald
Advanced Welding Process Simulation for Prediction and Control of Distortion and Residual Stresses in Automotive Sheet Metal Component Assembly2026-26-04121/16/2026
Welding simulations are transforming industrial manufacturing by enabling a predictive and first-time-right approach for process development. Advanced techniques such as Finite Element Analysis (FEA) help in accurate prediction of temperature distribution, residual stress, distortions and potential defects prior to physical welding which in turn support for addressing key challenges associated with Heat Affected Zones (HAZ) like distortion, fitment issues and post-weld cracking. Early integration of simulation in the development cycle significantly reduces lead time, enhances durability, and improves manufacturing efficiency. This study presents a simulation-based product development approach to mitigate post-weld crack generation issues in a complex multiple weld configuration of an automotive sheet metal assembly. The methodology adopts a two-stage framework: first, identifying the root cause of crack generating through baseline weld simulation; and second, implementing design optimizations to mitigate the issue as a sustainable solution. The baseline simulation conducted using the actual weld parameters and clamping conditions, successfully identified high-stress zones closely associated with observed crack formation. The simulated stress distribution was validated experimentally through X-ray Diffraction (XRD) measurements showing strong co-relation with the predicted results. Based on these insights, targeted design modification was introduced through simulation-based product development (SBPD) approach to reduce stress concentrations and minimize crack formation susceptibility. The work underlines the strategic benefits of integrating highly reliable welding simulations into product and process development. It demonstrates how simulation led insights can drive enhancements in weld quality, assembly accuracy and manufacturing robustness while delivering significant cost and performance benefits particularly within the demanding context of automotive production.
Nalawade, Rahul, Deshmukh, Kishor Pandurang, Vidhate, Digambar, Prakash, Ved, Dabhadkar, Mandar Mukund
Study the Tool Profile and Rotational Speed on Mechanical Attributes of FSW of Al 6063 Alloy05-19-03-00231/12/2026
Friction stir welding (FSW) of Al 6063 alloy plates of 6 mm thickness was investigated in the present study for exploring the mechanical attributes of the welded joints. The tool profile significantly influences the quality of joints produced by FSW. In the current study, the influence of tool profile and FSW process parameters on the FSW weld characteristics of similar joining of Al 6063 plates has been investigated. The effect of FSW tool rotational speed (TRS) and tool travel speed on the FSW weld properties, mainly microstructure characteristics, microhardness, and ultimate tensile strength (UTS), have been studied. Comparison of two different tool profiles, namely taper and cylindrical tool, has also been examined. The effect of transient temperature distribution has also been studied for varying FSW process parameters. When increasing the tool’s rotational speed from 800 to 1200 rpm at a fixed traverse speed of 80 mm/min, a rise in peak temperature is observed. Conversely, increasing the traverse speed from 80 to 100 mm/min while keeping the rotational speed constant at 1200 rpm results in a decrease in the peak temperature. Expanding the TRS from 800 to 1200 rpm—while keeping the welding speed constant at 80 mm/min—leads to a wider FSW weld nugget zone. Under the same welding conditions, the average microhardness of the nugget zone decreases as a result of this increase in TRS. Additionally, as the TRS increases from 800 to 1000 rpm at a steady traverse speed of 80 mm/min, the UTS improves and reaches a peak of about 235 MPa, which is close to the strength of the base material. When the rotational speed is further increased to 1200 rpm, the UTS drops to approximately 150 MPa, likely due to overheating, which may cause grain coarsening or softening in the welded region.
Kumar, Pramod, Kumar, Vikash, Kumar, Gulshan, Arif, Abdul, Prasad, Chitturi Ram, Zubairuddin, M.
Advances in Fiber Laser Welding for E-Mobility ManufacturingTBMG-544331/1/2026
High-power fiber lasers have become increasingly indispensable tools in automotive manufacturing over the past two decades. They are now widely deployed in welding and brazing applications for body-in-white, powertrains, engine components, and more.
Influence of Microstructure on the Mechanical Properties of Laser-Welded Joints between Different Classes of Automotive Steels2025-36-004912/18/2025
The need to reduce vehicle weight without compromising safety drives the use of advanced high-strength steels (AHSS) in the automotive industry. Laser welding is a widely employed technique for joining dissimilar materials due to its high precision and small heat-affected zone (HAZ). However, differences in the chemical composition and thermomechanical properties of the materials can create heterogeneous microstructures in the fusion zone (FZ) and HAZ, directly impacting the mechanical properties of the welded joint. This study aims to evaluate the relationship between microstructure and mechanical properties in laser-welded joints of dissimilar automotive steels. The objective is to understand how microstructural transformations affect weld strength, ductility, and toughness, contributing to process parameter optimization and improved structural performance. Microstructural analysis will be performed using optical microscopy, and mechanical tests, such as tensile testing and microhardness, will be conducted to correlate microstructural changes with the mechanical properties of the welded joint. It is expected that laser welding will result in a hardened HAZ due to the high cooling rate, which may reduce ductility and increase hardness in the welded region. Differences in the chemical composition of the base materials may lead to the formation of brittle phases in the FZ, affecting the joint's strength and toughness. The findings of this study will provide essential insights for improving the welding process and ensuring greater structural reliability in automotive applications.
Santos, dos Flávio Nunes, Reis de Faria Neto, dos Antonio, Dias, Erica Ximenes, Martins, Marcelo Sampaio, Santos Pereira, dos Marcelo
Boosting Welding Productivity with the GoFa CobotTBMG-5428112/1/2025
Finland-based Metos Oy, a manufacturer of professional stainless steel kitchen equipment, needed a welding solution that could deliver flawless, pressure-rated welds for small batches of high-spec products, which feature tubular structures and circular shafts that required continuous, precision welding.
Eyes of Robot Operating System for Future Hands2025-28-024611/6/2025
This paper presents a novel approach to automated robot programming and robot integration in manufacturing domain and minimizing the dependency on manual online/offline programming. Traditional industrial robots programming is typically done by online programing via teach pendants or by offline programming tools. This presents a major challenge as it requires skilled professionals and is a time-consuming process. In today’s competitive market, factories need to harness their full potential through smart and adaptive thinking to keep pace with evolving technology, customer demand, and manufacturing processes. This requires ability to manufacture multiple products on the same production line, minimum time for changeovers and implement robotic automation for efficiency enhancement. But each custom automation piece also demands significant human efforts for development and maintenance. By integrating the Robot Operating System (ROS) with vision-based 3D model generation systems, we address these challenges effectively. A ROS-based framework has been developed to automate the manual offline robot programming and enable real-time task optimization for performing manufacturing operations such as painting, welding, and torquing. The proposed framework—Capture → Connect → Compile → Create—using RGBD camera systems to record 3D point cloud data and part details. It then connects the complete points, annotate features, interprets edges and tasks to be performed and then convert into executable robotic programs. This method significantly reduces manual programming efforts and enables rapid deployment of robotic systems across diverse tasks. The paper outlines the system architecture, implementation methodology, and integration strategy within existing manufacturing lines. Through autonomous robotic programming, this approach enhances mass customization and boosts overall manufacturing efficiency. The proposed system offers a scalable solution for smart factories aiming to achieve high productivity, flexibility, and reduced operational costs.
Hepat, Abhijeet
Advanced Manufacturing Processes – Construction Equipment’s2025-28-024311/6/2025
With the global increase in demand for construction equipment, companies face immense pressure to produce more products in a competitive and sustainable way by utilizing advanced manufacturing technologies. Additionally, the need for data analytics and Industry 4.0 is increasing to take better decisions early in the development cycles and during the production phase. Advanced manufacturing processes & adopting Industry 4.0 is the only viable solution to address these challenges. However, the implementation of advanced manufacturing processes in heavy fabrication and construction equipment factories has been slow. A significant challenge is that the products being produced were originally designed for conventional manufacturing processes. When factories are becoming smart and connected through Industry 4.0 solutions, companies must reconsider many established assumptions about advanced manufacturing processes and their benefits. To maximize efficiency gains, improve safety standards, and enhance the reliability of automated manufacturing systems, engineers must adopt machine connectivity, advanced welding processes, sustainable welding, etc. This paper aims to investigate the requirements of the latest technologies in manufacturing and highlight the applications in construction equipment manufacturing. Key Projects 1. Weld Machine Connectivity (WMC) 2. High Deposition Welding (HDW) 3. High Frequency Mechanical Impact (HFMI)
Bhorge, Pankaj, Saseendran, Unnikrishnan, Rodge, Someshwar
Design for Welding Automation for Construction Equipment2025-28-024811/6/2025
Over the past 25 years, the heavy fabrication and construction equipment industry has experienced significant transformation. Driven by a global surge in demand for construction machinery, manufacturers are under increasing pressure to deliver higher volumes within shorter timelines and at competitive costs. This demand surge has been compounded by workforce-related challenges, including a declining interest among the new generation in acquiring traditional manufacturing skills such as welding, heat treatment, and painting. Furthermore, the industry faces difficulties in staffing third-shift operations, which are essential to meet production targets. The adoption of automation technologies in heavy fabrication and construction equipment manufacturing has been gradual and often hindered by legacy product designs that were optimized for conventional manufacturing methods. As the industry transitions toward smart, connected manufacturing environments under the industry 4.0 paradigm, it becomes imperative to re-evaluate existing design and production strategies. This paper aims to establish a framework for aligning product and process design with emerging automation capabilities and strategic business objectives. It advocates for a design-for-automation approach, wherein components are engineered to be compatible with robotic handling, automated guided vehicles (AGVs), conveyors, and other intelligent systems. By doing so, manufacturers can enhance operational efficiency, improve safety and reliability, and reduce time-to-market for new products.
Saseendran, Unnikrishnan, Bhorge, Pankaj
Development of Integral Forming for New “NMAX” YECVT Parts Using the Plate Forging Method2025-32-000511/3/2025
Yamaha Motor Engineering Co., Ltd. provides plastic processing technology based on fuel tank press forming technology, and is developing various plastic processing methods, including forging, and developing mold equipment to realize them. This time, the core parts of the YECVT unit mounted on Yamaha Motor Co., Ltd.'s small premium scooter "NMAX" were not made by welding individual parts to each other, but by integrally forming them from a single thick plate using the cold forming method, resulting in lightweight, compact, high-strength, high-precision parts. By incorporating a composite plastic processing method that takes advantage of the characteristics of the material while making full use of analysis technology and mold technology, we were able to develop a composite plastic processing method (plate forging method) that creates new added value and mass produce it. In addition,this development has made it possible to achieve a thickness increase of 1.7 times the standard material thickness as a mass production method.
Hongo, Hironari, Tamaru, Shogo, Uda, Shinnosuke
Optimization of Arc Welding Parameters for FB590 Hot-Rolled Ferritic-Bainitic Steel with 2.5 mm Thickness05-19-03-001810/31/2025
In this study, the optimization of robotic gas metal arc welding (GMAW) parameters for joining hot-rolled ferritic-bainitic FB590 steel sheets with a thickness of 2.5 mm was investigated. The main objective was to evaluate the effect of wire feed speed and welding speed on the penetration depth, throat thickness, and mechanical performance of the welded joint. A series of welding experiments were carried out with wire feed speeds ranging from 50 cm/min to 100 cm/min and welding speeds ranging from 5 cm/min to 15 cm/min. Tensile and microhardness tests were carried out to evaluate the structural integrity of the welded joints. The results show that increasing the wire feed speed significantly improves the weld penetration and throat thickness, especially at constant welding speeds. The most suitable combination was found to be 70 cm/min wire feed at 8 cm/min travel speed and 100 cm/min wire feed at 12 cm/min and 15 cm/min travel speeds. The microhardness in the heat-affected zone reached a maximum of 223 HV, while the tensile shear strength remained constant over all parameter ranges tested, indicating stable joint performance. These findings are consistent with previous literature and highlight the importance of precise parameter control in the welding of high-strength steel. This study provides valuable information for automotive applications where weld quality and repeatability are critical.
Babir, Naime, Üzel, Uğur
Aircraft Fire Protection for Helicopter Gas Turbine Powerplant and Related Systems InstallationsAIR1262A (Current)10/21/2025
This document is reissued for application to helicopters. It is primarily intended to apply to the engine or engines, but it shall also apply to fire protection of lines, tanks, combustion heaters, and auxiliary powerplants (APU). Post-crash fire protection is also discussed.
S-12 Powered Lift Propulsion Committee
FITTING END, INTEGRAL CENTERED WELD LIP, DESIGN STANDARDAS4697C (Current)10/21/2025
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Friction Stir Welding Robot Joins the Assembly LineTBMG-5405210/15/2025
Investigation of the Effect of Rotation Speed and Post-Weld Heat Treatment on Mechanical Properties and Structure of Friction Stir Welding AA6061 Joints05-19-02-00169/25/2025
This study aims at examining the effect of tool rotational speed on the microstructural and mechanical properties of friction stir welded joints of AA6061 aluminum alloy, both pre- and post-heat treatment. The quality of the joints was assessed initially through tensile, hardness, and charpy impact tests, as well as microscopic observations. During the second stage, solid solution heat treatments were conducted at 535°C, followed by aging on additional specimens welded at identical speeds. The latter underwent hardness tensile tests and microscopic examinations. A comprehensive assessment of the outcomes from various tests validated the influence of metallurgical phenomena, including recrystallization, precipitation, and structural defects on overall resistance. The results showed an improvement in strength, ductility, and impact energy was observed in the case of welding at high rotation speed (1400 rpm). At the same speed, ductility almost doubled after post-weld heat treatment. However, the treatment leads to a slight increase in strength and a decrease in ductility and impact energy at low speeds.
Bouchelouche, Fatima, Debih, Ali, Ouakdi, Elhadj
Rings, Flash Welded Ferritic and Martensitic Corrosion-Resistant SteelsAMS7493L (Current)9/23/2025
This specification covers flash welded rings made of ferritic and martensitic corrosion-resistant steels.
AMS F Corrosion and Heat Resistant Alloys Committee
Laser Welding for Polymer Tubing: A New Solution for Adhesive- and Additive-Free JoiningTBMG-537789/1/2025
Medical tubing is an essential component of countless healthcare applications, from intravenous (IV) and oxygen lines to catheters and diagnostic equipment. These tubes, often made of clear flexible polymers, must be produced to exacting standards: free of contaminants, strong under pressure, and biocompatible. However, the joining process to connect these tubes can introduce significant manufacturing challenges.
Identification Welding Wire, Tab Marking MethodAMS2816W (Current)7/21/2025
This specification covers procedures for tab marking of bare welding wire to provide positive identification of cut lengths and spools.
AMS B Finishes Processes and Fluids Committee
Welded, Flash-Controlled, Low-Carbon Steel Tubing Normalized for Bending, Double Flaring, Beading, Forming, and BrazingJ356_202506 (Current)6/30/2025
This SAE Standard covers normalized electric-resistance welded flash-controlled single-wall, low-carbon steel pressure tubing intended for use as pressure lines and in other applications requiring tubing of a quality suitable for bending, double flaring, beading, forming, and brazing. Material produced to this specification is not intended to be used for single flare applications, due to the potential leak path caused by the Inside Diameter (ID) weld bead or scarfed region. Assumption of risks when using this material for single flare applications shall be defined by agreement between the producer and purchaser. This specification also covers SAE J356 Type-A tubing. The mechanical properties and performance requirements of SAE J356 and SAE J356 Type-A are the same. The SAE J356 or SAE J356 Type-A designation define unique manufacturing differences between coiled and straight material. Nominal reference working pressures for this tubing are listed in ISO 10763 for metric tubing, and SAE J1065 for inch tubing. SAE J356 is produced in straight lengths that undergo a secondary heat treat operation. SAE J356 Type-A tubing is heat treated in-line to relieve stresses, and is produced in coil form. In an effort to standardize within a global marketplace and ensure that companies can remain competitive in an international market, it is the intent to convert to metric tube sizes, which will: Lead to one global system Guide users to preferred system Reduce complexity Eliminate inventory duplications
Metallic Tubing Committee
An Investigation into Friction Stir Surfacing of AA 6061-T6 Alloy on Low-Carbon Steel: Microstructural and Mechanical Analysis05-19-02-00136/30/2025
Friction stir surfacing is an advance surface modification technique, which is functionally evolved from the friction stir welding process. However, the fundamental reason behind the joining of Al/steel is difficult due to the formation of hard and brittle intermetallic compounds (IMC). To address the problem of IMC formation, the current study suggested an alternate production technique with solid-state friction surfacing deposition. In this work, the adhesion mechanism and metallurgical properties of solution-treated AA6061-T6 aluminum alloy cladding over a low-carbon steel IS2062 substrate were investigated. Impact procedural factors (axial frictional force, spindle speed, table traverse speed, consumable rod diameter, and substrate roughness) were examined. Push-off and hardness tests were used to inspect the mechanical properties of cladded samples. 67–77± HV hardness is observed at the interface of the cladded cross-section. A push-off strength of 9 kN was achieved, indicating effective bonding between the AA6061-T6 alloy and the low-carbon steel substrate. Microexamination indicated that there is clear bonding through broken asperities, which are due to mechanical interlocking. The suggested approach can likewise be used with other dissimilar combinations that are mutually intractable.
Badheka, Kedar Hiteshkumar, Sharma, Daulat Kumar, Badheka, Vishvesh
Increasing Wear Strength and Life Cycle of Tamping Machine Tool by Silicon Carbide Coating for Railway Maintenance05-19-02-00116/19/2025
When a train passes continuously over a section of the track, the track gradually moves away from the intended vertical and horizontal alignment with time and repeated use. Regular maintenance on the track, such as leveling, lifting, lining, and tamping, is necessary to maintain the optimal geometry of the track. Ballast is leveled and squeezed by hydraulic rams in tamping machines. The tamping is a process of ballast packing under railway tracks. In current system a set of tungsten carbide chips are attached either by welding or by coating on tamping tool tip made of EN24 steels. These tungsten carbide chips directly come in contact with the ballasts. After few tamping works, gradually these chips torn out and need to be replaced after certain period. Tungsten carbide is a costly material, therefore this research deals with replacement of tungsten carbide with silicon carbide (easily available cheaper) coating used for tamping tools tip. The study consists of microstructural examination of both materials. The SEM analysis shows that SiC coatings provide a more uniform, dense, and defect-free surface with finer grain structures. SiC coatings adhere better to the EN24 steel substrate, as seen in optical microscopy images. Result shows that tungsten carbide-coated sample exhibited the higher average wear rate, and the silicon carbide-coated sample displayed the lower average wear rate.
Mishra, Mamta, Pandey, Manas, Singh, Shruti, Srivastava, Sanjay, Kumar, Jitendra
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