Browse Topic: Welding

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Influence of varying shoulder profiles in pin-less tool on friction stir welding of thin plates2026-28-0028To be published on 02/01/2026
This study explores the thermal and mechanical characteristics of Friction Stir Welding (FSW) using pin-less tools with varied shoulder geometries to weld 2 mm dissimilar plates. FSW is a solid-state joining technique known for minimizing weld defects and enhancing joint integrity, particularly in the applications requiring high precision and low thermal distortion. Using simulation-based analysis via ANSYS, three custom-designed tool profiles are considered (i.e) spiral, concentric, and diamond tip, were evaluated. The rotational speeds considered are 500, 1000, and 3000 rpm at a constant traverse speed of 90 mm/min. The 3D models of the FSW tool with required shoulder profiles and thin plates are developed using Solid works. The tool and plates are characterized using tungsten carbide and aluminium-magnesium for workpieces. The simulations focused on key field variables including, temperature distribution, residual stress, and deformation on the welded plates. Results indicated that
Nelson, N Rino
Study of Style wheel rim failure Due to Rim and disc assembly interference2026-26-0541To be published on 01/16/2026
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
Effect of pipe bending by rotary tube bending process on durability of frame structure2026-26-0370To be published on 01/16/2026
For Original Equipment Manufacturers (OEMs), ensuring the overall quality of two-wheeler frames hinges on robust process capability and meticulous design considerations. A comprehensive Computer-Aided Engineering (CAE) simulation approach, integrating manufacturing processes and design elements, is vital for achieving optimal durability. This study focuses on developing such an approach through detailed finite element analysis of Cold Electric Welded (CEW) annealed round pipes used in frame construction. We simulate the bending process, capturing structural deformation and residual stresses. A 3D mechanical model with realistic tooling geometries and contact interactions accurately represents shape changes, ovality, and wall thickness redistribution. Unlike Electric Resistance Welded (ERW) pipes, CEW pipes, due to annealing, offer a stress-free initial state, allowing precise deformation analysis. Simulation results demonstrate significant geometric alterations in the bend zone
Rajwani, Ishwar, khare, Saharash
Failure Analysis of Dissimilar Metal Weld Joint of an Air Spring Bracket within an Automotive Active Seat Suspension System2026-26-0487To be published on 01/16/2026
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
Patale Jr, Reshma, PINJARI, JAYANT NAMDEV, BALI, SHIRISH
Eyes of Robot Operating System for Future Hands2025-28-024611/06/2025
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
Hepat, Abhijeet
Advanced Manufacturing Processes – Construction Equipment’s2025-28-024311/06/2025
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
Bhorge, Pankaj, Saseendran, Unnikrishnan, Rodge, Someshwar
Design for Welding Automation for Construction Equipment2025-28-024811/06/2025
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
Saseendran, Unnikrishnan, Bhorge, Pankaj
Development of Integral Forming for New “NMAX” YECVT Parts Using the Plate Forging Method2025-32-000511/03/2025
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
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
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
Investigation of the Effect of Rotation Speed and Post-Weld Heat Treatment on Mechanical Properties and Structure of Friction Stir Welding AA6061 Joints05-19-02-001609/25/2025
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
Bouchelouche, Fatima, Debih, Ali, Ouakdi, Elhadj
Rings, Flash Welded Ferritic and Martensitic Corrosion-Resistant SteelsAMS7493L (Current)09/23/2025
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-5377809/01/2025
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)07/21/2025
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)06/30/2025
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
Metallic Tubing Committee
An Investigation into Friction Stir Surfacing of AA 6061-T6 Alloy on Low-Carbon Steel: Microstructural and Mechanical Analysis05-19-02-001306/30/2025
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
Badheka, Kedar Hiteshkumar, Sharma, Daulat Kumar, Badheka, Vishvesh
Increasing Wear Strength and Life Cycle of Tamping Machine Tool by Silicon Carbide Coating for Railway Maintenance05-19-02-001106/19/2025
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
Mishra, Mamta, Pandey, Manas, Singh, Shruti, Srivastava, Sanjay, Kumar, Jitendra
Advanced Laser Welding Techniques for Titanium Pacemaker Housing: Achieving Precision, Reliable and Hermetic SealingTBMG-5325806/03/2025
A pacemaker is a small device that helps control your heartbeat so you can return to your normal life. It has three main parts: a pulse generator that creates electrical signals, a controller-monitor that manages these signals, and leads that deliver the signals to the heart. One key benefit of the pacemaker is its strong titanium casing. Titanium is very strong and lightweight, and it is biocompatible, meaning it works well with the body without causing harmful reactions. This metal is highly resistant to corrosion, which helps keep the casing intact and protective even when exposed to bodily fluids.
Wire Feed Laser Welding for Battery Pack Aluminum Enclosure Manufacture in EVsTBMG-5321006/01/2025
Comparison of Different Joining Techniques as a Benchmark for Integrally Joined Thermoformed Components Based on Tailored rCF Organosheets2025-01-017005/02/2025
Climate-neutral aviation requires resource-efficient composite manufacturing technologies and solutions for the reuse of carbon fibers (CF). In this context, thermoplastic composites (TPC) can make a strong contribution. Thermoforming of TPC is an efficient and established process for aerospace components. Its efficiency could be further increased by integration of joining processes, which would otherwise be separate processes requiring additional time and equipment. In this work, an integrative two-step thermoforming process for hollow box structures is presented. The starting point are two organosheets, i.e. fiber-reinforced thermoplastic sheets. First, one of the organosheets, intended for the bottom skin of the uplift structure, is thermoformed. After cooling, the press opens, the organosheet remains in the press and an infrared heater is pivoted in, to locally heat up just the joining area. Meanwhile, a second organosheet, intended for the top skin, is heated and thermoformed and
Vocke, Richard, Seeßelberg, Lorenz, Focke, Oliver, Dietrich, Jan Yorrick, Jobke, Katrin, Albe, Christopher, May, David
Material Adapted Method for the Repair of Curved Thermoplastic Composite Structures by Induction Welding of Patches2025-01-016505/02/2025
Thermoplastic fiber-reinforced polymer composites (TPC) are gaining relevance in aviation due to their high specific strength, stiffness, potential recyclability and the ability to be repaired thanks to their meltability. To maximize their potential, efficient repair methods are needed to maintain aircraft safety and structural integrity. This article introduces a novel repair technique for damaged TPC structures, involving the joining of a repair patch with induction welding using a susceptor material. The susceptor consists of a material with high electrical conductivity and magnetic permeability and therefore reacts stronger to the electromagnetic field than the composite, even if the composite is carbon fiber based. I. e. the thermal energy is specifically concentrated in the repair area. In this study, the susceptor was placed on the patch and also in the welding zone. The repair process begins by identifying and preparing the damaged area, followed by precise scarfing. Care is
Geiger, Markus, Glaap, Anton, Schiebel, Patrick, May, David
Ultrasonic Welding: Key Considerations for Designing Medical WearablesTBMG-5316505/01/2025
Not only the use, but also the wearing time of medical wearables continues to increase in modern healthcare. However, to ensure that wearable products do not cause skin irritation, product designers must consider the moisture vapor transmission rate (MVTR) during development. It plays an important role in skin compatibility and wearing comfort — and can be decisively influenced by the right joining technology.
Transient Failure Analysis of Alloy Steel Welded Joints under Sudden Tension Load Condition05-18-03-002504/21/2025
The study aims to evaluate the transient failure behavior of welding joints that are exposed to sudden tensile loading. The Mohr–Coulomb criterion’s fundamental theories are examined and evaluated. The failure function of Mohr’s envelope is first expanded into a polynomial in terms of the stress components (σp , τxy ) on the failure region up to the third order. Using ANSYS software, the transient failure response of welding joints was simulated. The Runge–Kutta fourth-order computational technique was employed to perform numerical analysis on transient failure response. Python software is used to develop a computer code for the time-dependent failure response of welding joints. The welded joint specimen is tested with the help of a UTM machine. The analytical results are compared with experimental results. A fractography study was carried out on the welded joint of the failure surface. In this context, the main focus is on SEM and EDS methods to determine the exact type of failure
Chavan, Shivaji, Raut, D. N.
Prediction Method of Strength Robustness Affected by Arc Welding Sectional Dimensions2024-32-003804/18/2025
The arc welding process is essential for motorcycle frames, which are difficult to form in one piece because of their complex shapes, because a single frame has dozens of joints. Many of the damaged parts of the frames under development are from welds. Predicting the strength of welds with high reliability is important to ensure that development proceeds without any rework. In developing frames, CAE is utilized to build up strength before prototyping. Detailed weld shapes are not applicable to FE models of frames because weld shapes vary widely depending on welding conditions. Even if CAE is performed on such an FE model and the evaluation criteria are satisfied, the model may fail in the actual vehicle, possibly due to the difference between CAE and actual weld bead geometry. Therefore, we decided to study the extent to which the stresses in the joint vary with the variation of the weld bead geometry. Morphing, a FE modeling method and design of experiment method, was utilized to
Hada, Yusuke, Sugita, Hisayuki
Electron-Beam Welding For Fatigue Critical ApplicationsAMS2680D (Current)04/14/2025
This specification defines the procedures and requirements for joining metals and alloys using the electron-beam welding process.
AMS B Finishes Processes and Fluids Committee
A Modified Johnson-Cook Model Considering Strain-Temperature Coupling for Welding Simulation of Aluminum Alloy Bumper2025-01-824304/01/2025
The metal inert-gas (MIG) welding technique employed for aluminum alloy automotive bumpers involve a complex thermo-mechanical coupling process at elevated temperatures. Attaining a globally optimal set of model parameters continues to represent a pivotal objective in the pursuit of reliable constitutive models that can facilitate precise simulation of the welding process. In this study, a novel piecewise modified Johnson-Cook (MJ-C) constitutive model that incorporates the strain-temperature coupling has been proposed and developed. A quasi-static uniaxial tensile model of the specimen is constructed based on ABAQUS and its secondary development, with model parameters calibrated via the second-generation non-dominated sorting genetic algorithm (NSGA-II) method. A finite element simulation model for T-joint welding is subsequently established, upon which numerical simulation analyses of both the welding temperature field and post-welding deformation can be conducted. The results
Yi, Xiaolong, Meng, Dejian, Gao, Yunkai
Structural Seam Weld Optimization with Efficient Approach of DFSS2025-01-824804/01/2025
In automotive engineering, seam welds are frequently used to join or connect various parts of structures, frames, cradles, chassis, suspension components, and body. These welds usually form the weaker material link for durability and impact loads, which are measured by lab-controlled durability and crash tests, as well as real-world vehicle longevity. Consequently, designing robust welded components while optimizing for material performance is often prioritized as engineering challenge. The position, dimensions, material, manufacturing variation, and defects all affect the weld quality, stiffness, durability, impact, and crash performance. In this paper, the authors present best practices based on studies over many years, a rapid approach for optimizing welds, especially seam welds, by adopting Design For Six Sigma (DFSS) IDDOV (Identify, Define, Develop, Optimization, and Verification) discrete optimization approach. We will present the case testimony to show the approach throughout
Qin, Wenxin, Li, Fan, Pohl, Kevin J., Pentapati, Venkat
Analysis of Residual Stress in Arc Welded Lap Joints of High Strength Steel Sheets and Welding Wire Using Material Properties during Heating and Cooling2025-01-831304/01/2025
An approach for the precise analysis of residual stress in arc welded lap joints of high strength steel sheets is proposed. This approach involves the development of a method for measuring material properties during both the heating and cooling processes. The measured material properties are then utilized in a thermal elastic-plastic finite element method (FEM) analysis of the welding residual stresses in the lap joints. Analysis accuracy is investigated by comparing the results using material properties measured during heating, cooling, or both. The maximum temperature distribution on the surface of the heat affected zone (HAZ) is measured and accurately predicted by a welding thermal conduction analysis. When the material properties measured only during heating, only during cooling, or during both heating and cooling were used in the thermal elastic-plastic FEM analysis, the results showed that the stress histories in arc welded joints of 780 MPa high strength steel sheets are
Ohnishi, Yoichiro, Sato, Kentaro, Ma, Ninshu, Narasaki, Kunio, Weihao, Li, Yasuda, Koichi
Self-Piercing Riveting (SPR) of Magnesium High Pressure Die Casting and Dissimilar Materials2025-01-823104/01/2025
Solid state joining processes are attractive for magnesium alloys as they can offer robust joints without the porosity issue typically associated with welding of magnesium and dissimilar materials. Among these techniques, Self-Piercing Riveting (SPR) is a clean, fast and cost-effective method widely employed in automotive industry for aluminum alloys. While SPR has been proven effective for joining aluminum and steel, it has yet to be successfully adapted for magnesium alloy castings. The primary challenge in developing magnesium SPR technology is the cracking of the magnesium button, which occurs due to magnesium's low formability at room temperature. Researchers and engineers approached this issue with several techniques, such as pre-heating, applying rotation to rivets, using a sacrificial layer and padded SPR. However, all these methods involve the employment of new equipment or introduction of extra processing steps. The aim of this work is to develop a SPR technique which adapts
Tabatabaei, Yousef, Wang, Gerry, Weiler, Jonathan
Weld Fatigue Life Variational Assessment for Exhaust System Using Monte Carlo Approach2025-01-819804/01/2025
Parts in automotive exhaust assembly are joined to each other using welding process. When the exhaust is subjected to dynamic loads, most of these weld joints experience high stresses. Hence it should be ensured that the exhaust assembly is designed to meet the requirements of exhaust durability for the estimated life of the vehicle. We also know that all parts used in manufacturing of exhaust system have inherent variations with respect to sheet metal thickness, dimensions and shape. Some parts like flex coupling and isolators have high variations in their stiffness based on their material and manufacturing processes. This all leads to a big challenge to ensure that the exhaust system meets the durability targets on a vehicle manufactured with all these variations. This works aims to evaluate the statistical spread in weld life of an exhaust with respect to inherent variations of its components. For the purpose of variational analysis, a Design of Experiments (DOE) is done where
Ramamoorthy, Rajapandian, Bazzi, Ramzi
Elevating Welding Operations with Collaborative AutomationTBMG-5280204/01/2025
Mesekon Oy, a Finnish welding manufacturer that produces complex welded steel structures for the marine, energy, and paper industries, needed a flexible and collaborative solution to improve efficiency, reduce defects, and enhance workplace ergonomics by automating repetitive and physically demanding welding operations.
Steel, Corrosion- and Heat-Resistant, Welding Wire 15Cr - 25.5Ni - 1.3Mo - 2.2Ti - 0.006B - 0.30V (A286)AMS5804J (Current)03/25/2025
This specification covers a corrosion- and heat-resistant steel in the form of welding wire.
AMS F Corrosion and Heat Resistant Alloys Committee
Machine Learning–Based Modeling for Predicting the Lap Shear Strength of High-Strength Steel Laser Lap Welds05-18-04-002903/20/2025
This study investigates the nonlinear correlation between laser welding parameters and weld quality, employing machine learning techniques to enhance the predictive accuracy of tensile lap shear strength (TLS) in automotive QP1180 high-strength steel joints. By incorporating three algorithms: random forest (RF), backpropagation neural network (BPNN), and K-nearest neighbors regression (KNN), with Bayesian optimization (BO), an efficient predictive model has been developed. The results demonstrated that the RF model optimized by the BO algorithm performed best in predicting the strength of high-strength steel plate-welded joints, with an R2 of 0.961. Furthermore, the trained RF model was applied to identify the parameter combination for the maximum TLS value within the selected parameter range through grid search, and its effectiveness was experimentally verified. The model predictions were accurate, with errors controlled within 6.73%. The TLS obtained from the reverse-selected process
Han, Jinbang, Ji, Yuxiang, Liu, Yong, Liu, Zhao, Wang, Xianhui, Han, Weijian, Wu, Kun
Nickel-Iron Alloy, Corrosion- and Heat-Resistant, Welding Wire, Consumable Electrode Remelted or Vacuum Induction Melted, 12.5Cr - 42.5Ni - 6.0Mo - 2.7Ti - 0.015B - 35Fe (Alloy 901)AMS5830D (Current)02/25/2025
This specification covers a corrosion- and heat-resistant nickel-iron alloy in the form of welding wire.
AMS F Corrosion and Heat Resistant Alloys Committee
Steel, Corrosion- and Heat-Resistant, Welding Wire 9.0Mn - 20Cr - 6.2Ni - 0.20N (21-6-9, Nitronic® 40W)AMS5818D (Current)02/25/2025
This specification covers a corrosion- and heat-resistant steel in the form of welding wire.
AMS F Corrosion and Heat Resistant Alloys Committee
Microstructural and Mechanical Characterization of Overhanging AA 4043 Structures Fabricated by CMT Pulse Based WAAM for Automotive Applications2025-28-014002/07/2025
This study investigates the fabrication and characterization of overhanging structures using the Cold Metal Transfer (CMT) pulse based Wire Arc Additive Manufacturing (WAAM) technique, specifically targeting automotive applications on commercial aluminum components. Focusing on optimal welding strategies for overhanging structures, components are fabricated by providing offsets during consecutive deposition of layers, thus producing parts with angles of 45°, 60° and 90° inclinations from the substrate. Three specimens undergo around twenty-five layers of deposition, resulting in structurally sound joints within this specified angle range. AA 4043 electrode is utilized, and welding parameters are optimized through trials by verifying with bead on plate deposition. Successful outcomes are achieved within the specified angle range, though challenges arise beyond 60°, complicating the maintenance of desired weld quality. The study further evaluates the microstructure, microhardness, and
A, Aravind, S, Jerome, A, Rahavendran
Finite Element Fatigue Life Prediction and Test Correlation for Seam Welded Joints in Sheet Metal Assemblies2025-28-005402/07/2025
Tractors, as agricultural machines consisting of various interconnected assemblies, work in unison to perform specific functions and achieve desired outputs. Among these assemblies, the Hood Assembly, Firewall Assembly, Scuttle Assembly, Fuel Tank Assembly, Fender Assembly, Floor Panel Assembly, and Footstep Assembly are all produced through sheet metal fabrication. The components of these assembly are made from sheet metal and are joined together using various techniques, such as bolts, welds, and others. The inherent characteristics of welding processes generally results in welded joints having lower fatigue strength compared to the individual parts being joined. Moreover, welds are commonly applied at geometric features or areas where the section changes within a structure. As a result, even in a structurally sound design, welded joints are often more vulnerable to fatigue failure. Hence, a comprehensive assessment of the durability of a welded structure requires placing
Kumar, Arun, Pandey, Manoj Kumar, Thirugnanam, Vivekanndan, Mani, Suresh, Redkar, Dinesh
Research on the Optimization of Metal Bipolar Plate Welding Process Based on Box-Behnken Design-Response Surface Method2025-01-708101/31/2025
Metal bipolar plates are important components of fuel cells, playing a role in conducting electricity, gas, and heat during the operation of fuel cells. The sealing and joint quality of the bipolar plates have a significant impact on the performance and service life of fuel cell stacks. In actual production, laser technology is often used for welding bipolar plates, and the welding quality is ensured by laser process parameters when using the same equipment. Therefore, in order to further optimize the laser welding process of metal bipolar plates, this paper selects three laser parameters for single-factor analysis to evaluate the impact of each parameter on laser welding quality. The Box-Behnken design-response surface method is used for multi-factor analysis, with process parameters as inputs and weld quality parameters as outputs, to assess the sensitivity of each laser process parameter to laser welding quality, and to fit a nonlinear function. Based on the results, the optimal
Li, Wei, Chang, Guofeng, Xu, Huasheng, Huang, Ziheng
Multi-Objective Welding Optimization for AA5052 Using Taguchi-Fuzzy Approach05-18-03-001801/24/2025
This study investigates the influence of tungsten inert gas (TIG) welding parameters on the dilution and hardness of AA5052 aluminum alloy. Employing Taguchi’s L27 orthogonal array, the research systematically explores the effects of current, voltage, and welding speed. Analysis of the experimental data utilizes signal-to-noise ratio, analysis of variance (ANOVA), and regression techniques. The study compares a traditional regression model with a fuzzy logic approach for result validation, finding that the latter exhibits marginally better predictive accuracy. Optimal welding parameters are identified as 150 A current, 20 V voltage, and 45 mm/s welding speed, yielding a maximum dilution of 52.81% and hardness of 145.3 HV 0.5. Current emerges as the most significant factor influencing both dilution and hardness. Microstructural examination, hardness profiling, and tensile testing of specimens welded under optimized conditions reveal a characteristic hardness distribution across the weld
Omprakasam, S., Raghu, R., Balaji Ayyanar, C.
Laser Welding Applied to Complex Phase Steel2024-36-015912/20/2024
The development of advanced high-strength steels has become essential in the production of lightweight, safe, and more economical vehicles within the context of the automotive industry. Among the advanced high-strength steels, complex phase steels stand out, characterized by their high formability and high energy absorption and deformation capacity. Laser welding is a technique that applies laser using high energy density as a heat source. It has the advantages that the high welding speed and low heat input compared to other welding methods cause a decrease in deformation, and the narrow width of the weld bead and heat-affected zone allows for the welding of complex parts that would be difficult for other welding methods. Based on a study of a complex phase steel, an analysis was made of the microstructures observed by optical microscopy, the grain boundaries and certain phases contained in this microstructure, as well as the microstructures of each area in the laser welding region
Dias, Erica Ximenes, Reis de Faria Neto, Antonio, Castro, Thais Santos, Martins, Marcelo Sampaio, Santos Pereira, Marcelo
Tensile Strength Analysis of Electron Beam Welded AA2024 Aluminum Alloy Joints2024-01-522012/10/2024
The AA2024 aluminum alloy is a precipitate-hardening material renowned for its exceptional strength and corrosion resistance, making it a preferred choice for various applications in industries such as aircraft and automobile manufacturing. However, it is challenging to weld using fusion welding processes due to differences in melting points between the aluminum base material and its oxide layer. Consequently, this often results in issues such as partially melted zones, alloy segregation, and hot cracking. In this investigation, electron beam welding was employed to minimize heat input and prevent the formation of coarse grains in the heat-affected zone. Observations revealed that the joint achieved a maximum strength of 285 MPa, representing 62% of the base material's strength. This improvement in strength can be ascribed to the establishment of fine and recrystallized grains at the weld interface, along with the presence of copper aluminide strengthening precipitates.
Rajesh, A., Karthick, S., Mallieswaran, K., Shanmugam, Rajasekaran
Establishing an Empirical Relationship to Predict the Tensile Strength of a FSSW-AA7075 Aluminum Alloy with Mild Steel2024-01-522412/10/2024
In this study, an investigation was conducted on friction stir spot-welded AA7075 aluminum alloy with mild steel. Fusion welding of these two materials presents challenges because of differences in melting points and metallurgical incompatibility. To overcome these challenges, friction stir spot welding was employed for joining these materials. Trial runs were conducted based on a central composite rotatable design matrix, which encompassed four factors at five levels: tool rotational speed, plunge rate, dwell time, and tool diameter ratio. Shear tests were conducted to evaluate the joint strength, and subsequently, an empirical equation was developed via analysis of variance. Notably, a joint fabricated under specific conditions demonstrated exceptional strength, with the highest fracture load of 9.56 kN. These optimal parameters included the tool rotational speed, plunge ratio, dwell time and diameter ratio of 1000 rpm, 4 mm/min, 5 sec and 3.0. This achievement underscores the
Salman, Riyam Abd Alrazaq, Mohammed, Khidhair Jasim, Rajan, Rajthilak Krishnan, Smaisim, Ghassan Fadhil, Siva Subramanian, R.
Impact of Tool Rotational Speed and Welding Speed on Tensile Strength of Friction Stir Welded AA5083 Aluminum Alloy Joints2024-01-520512/10/2024
One of the most common materials in the fabrication sectors, especially in the auto sector, is Aluminum alloy. Owing to its low strength to weight ratio, it could be a good fit for a number of applications. The cold working procedure may strengthen the 5XXX series Aluminum alloy, which is not heat treatable and it is also challenging to fuse these alloys together using fusion welding processes. In Recent days, a solid-state welding procedure, Friction Stir Welding (FSW) is used to join this alloy. The impact of FSW process parameters on tensile strength of the joint is examined in this study. Based on the outcomes of the experiment, the highest tensile strength is observed at 900 RPM tool rotation, 100 mm/min welding speed, 1.5-degree tilt angle, and 3.0 tool diameter ratio. Superior strength (246 MPa) of this parameter over its competitors can be attributed to the balanced material flow and the formation of finer grains in the weld region.
Maram, Sreenivasulu Reddy, Kumar, M. Vinoth, Hariram, V.
Investigation on Mechanical and Metallurgical Characterization of Micro-Alloyed Steel Produced by Friction Stir Welding (FSW)2024-01-520312/10/2024
This research investigates the impact of friction stir welding (FSW) used to join micro-alloyed steel, on the material and its mechanical characteristics. FSW increases the metallurgical and mechanical qualities of joints made from micro-alloyed steel. However, Friction Stir Welding has produced only modest improvements in connecting steels. Automobile chassis, offshore platforms, oil and gas pipelines, mining, shipbuilding and railroad carriages, pressure vessels, bridges, and storage tanks are just some of the many places and find micro-alloyed steels employed. Frictional heat and tool movement over the joint cause micro defects occurred. Tungsten carbide tools are used in this investigation. Welding shares the same process characteristics, such as the tool's rotating speed (900 rpm) and axial force (10 kN). The table's traverse speed options are available, including 50 mm/min, 60 mm/min, and 70 mm/min. Vickers microhardness testing machines and tensile testing machines are used to
Rajan, C. Sakthi, Kumar, N. Mathan, Kumar, K. Vetrivel, Kannan, S., Soundararajan, S.
Leveraging Welding Spot Quality Control Using Camera Vision System2024-28-026412/05/2024
Spot welds are integral to automotive body construction, influencing vehicle performance and durability. Spot welding ensures structural integrity by creating strong bonds between metal sheets, crucial for maintaining vehicle safety and performance. It is highly compatible with automation, allowing for streamlined production processes and increased efficiency in automotive assembly lines. The number and distribution of spot welds directly impact the vehicle's ability to withstand various loads and stresses, including impacts, vibrations, and torsion. Manufacturers adhere to strict quality control standards to ensure the integrity of spot welds in automotive production. Monitoring spot weld count and weld quality during manufacturing processes through advanced inspection techniques such as Image processing by YOLOv8 helps identify the number of spots and quality that could compromise safety. Automating quality control processes is paramount, and machine vision offers a promising
Kadam, Shubham Narayan, Dolas, Aniket, Mishra, Jagdish
Nickel Alloy, Corrosion- and Heat-Resistant, Welded Tubing 57Ni - 19.5Cr - 13.5Co - 4.2Mo - 2.9Ti - 1.4Al - 0.006B - 0.08Zr (Waspaloy) Consumable Electrode Remelted or Vacuum Induction Melted, AnnealedAMS5586J (Current)12/05/2024
This specification covers a corrosion- and heat-resistant nickel alloy in the form of welded and drawn tubing 0.125 inch (3.18 mm) and over in nominal OD and 0.015 inch (0.38 mm) and over in nominal wall thickness.
AMS F Corrosion and Heat Resistant Alloys Committee
Evaluation of Joining Performance of Different Coated Steel Sheets Used in Automotive Applications2024-28-016312/05/2024
To meet the corrosion target of automotive vehicles, different coated steel sheets are used in various parts of the body in white (BIW), chassis, and powertrain. Hot dip galvanized (GI) and hot hip galvannealed (GA) are the two most commonly used steel sheets worldwide. Other coatings, such as Zn-Ni, Al-Si, Zn plating, and electro-galvanized zinc coating, are application-specific coatings that are used suitably to meet different performance requirements. To meet the robust corrosion and performance requirements, there is a trend of increasing the use of coated steel sheets in automotive vehicles. While different coated steels have different corrosion performance, they also exhibit different joining and paint adhesion performance. Spot welding is one of the most common technique used for joining automotive parts. Joint strength majorly depends on steel base material grade, chemistry and properties. However, coating on base material also influence joining performance. Major challenge is
Jain, Vikas, Misal, Swapnali, Deshmukh, Mansi, Paliwal, Lokesh
Aluminum Alloy, Flash-Welded Rings 5.6Zn - 2.5Mg - 1.6Cu - 0.23Cr (7075-T73) Solution and Precipitation Heat TreatedAMS4174F (Current)12/05/2024
This specification covers an aluminum alloy in the form of flash-welded rings 0.062 to 4.499 inches (1.57 to 114.27 mm), inclusive, in radial thickness with cross-sectional areas up to 32 square inches (206 cm2) (see 8.6).
AMS D Nonferrous Alloys Committee
Comprehend Dynamic Behaviour of Vehicle Body for Refined NVH Performance2024-28-026512/05/2024
Modal performance of a vehicle body often influences tactile vibrations felt by passengers as well as their acoustic comfort inside the cabin at low frequencies. This paper focuses on a premium hatchback’s development program where a design-intent initial batch of proto-cars were found to meet their targeted NVH performance. However, tactile vibrations in pre-production pilot batch vehicles were found to be of higher intensity. As a resolution, a method of cascading full vehicle level performance to its Body-In-White (BIW) component level was used to understand dynamic behavior of the vehicle and subsequently, to improve structural weakness of the body to achieve the targeted NVH performance. The cascaded modal performance indicated that global bending stiffness of the pre-production bodies was on the lower side w.r.t. that of the design intent body. To identify the root cause, design sensitivity of number and footprint of weld spots, roof bows’ and headers’ attachment stiffness to BIW
Titave, Uttam Vasant, Zalaki, Nitin, Naidu, Sudhakara
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