Ultrasonic welding is increasingly used in industry. In this paper, the influence of ultrasonic welding parameters (USW) on the joint strength and quality was analysed. The properties of the USW joints depend on many factors. The work focuses on the influence of the technological parameters and the surface properties of welded EN Cu-ETP copper sheets with a thickness of 1 mm. The impact of the process parameters, such as welding time, pressure, vibration amplitude and the surface roughness on the lap shear strength and the metallographic weld properties was analysed. The welding energy for each variant was also determined. The research was conducted on the basis of a full factorial design of experiments. The optimal process parameters were determined to obtain high-quality joints in terms of strength and weld quality. Based on the presented experimental study, it was demonstrated that the ultrasonic vibration amplitude has the greatest impact on the joint strength. A surface preparation with acetone resulted in the highest tensile strength and welding energy and, making any additional surface treatment prior to welding unnecessary.

The demand for joining dissimilar metals has exponentially increased due to the global concerns about climate change, especially for electric vehicles in the automotive industry. Ultrasonic welding (USW) surges as a very promising technique to join dissimilar metals, providing strength and electric conductivity, in addition to avoid metallurgical defects, such as the formation of intermetallic compounds, brittle phases and porosities. However, USW is a very sensitive process, which depends on many parameters. This work evaluates the impact of the process parameters on the quality of ultrasonic spot welds between copper and aluminium plates. The weld quality is assessed based on the tensile strength of the joints and metallographic examination of the weld cross-sections. Furthermore, the welding energy is examined for the different welding conditions. This is done to evaluate the influence of each parameter on the heat input resulting from friction at the weld interface and on the weld quality. From the obtained results, it was possible to optimise parameters to achieve satisfactory weld quality in 1.0 mm thick Al–Cu plate joints in terms of mechanical and metallurgical properties.

This study aims to demonstrate the capability of the digital image correlation (DIC) technique for evaluating full-field residual stresses in wire and arc additive manufactured (WAAM) components. Investigations were carried out on WAAM steel parts (wall deposited on a substrate) with two different wall heights: 24 mm and 48 mm. Mild steel solid wire AWS ER70S-6 was used to print WAAM walls on substrates that were rigidly clamped to H-profiles. DIC was used to monitor the bending deformation of WAAM parts during unclamping from the H-profiles, and residual stresses were calculated from the strain field captured during unclamping. Residual stresses determined from the proposed DIC-based method were verified with an analytical model and validated by the results from established residual stress measurement techniques, i.e., the contour method and X-ray diffraction.

Additive manufacturing (AM) processes are playing a significant role in several industrial sectors such as construction and machine building industries, involving a wide variety of metallic materials. Among these, the AM of aluminium alloys has developed significantly over the last decade, mainly through Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) processes. Despite the many advantages of AM technology, some large or complex products cannot be produced entirely without the use of conventional manufacturing and joining processes, generally for financial or operational reasons. In this way, the ability to join conventionally and additively manufactured components or parts represents a crucial step towards their future use and the consolidation of conventional and additive manufacturing technologies. Despite the growing interest in AM technologies, there is still a significant lack of information on the joining of conventionally and additively manufactured components. The present work proposes a first review of the literature evaluating the weldability of AM aluminium alloys. The focus is on the use of fusion and solid-state welding processes and analysing the achieved microstructural evolution and mechanical properties. A clear relationship is observed between the AM technology used to produce the part, and the physical principles of the joining process. In addition, the gaps in the literature are highlighted to enable focused future work.

Ultrasonic welding (USW) is a solid-state welding process based on the application of high frequency vibration energy to the workpiece to produce the internal friction between the faying surface and the local heat generation required to promote the joining. The short welding time and the low heat input, the absence of fumes, sparks or flames, and the automation capacity make it particularly interesting for several fields, such as electrical/electronic, automotive, aerospace, appliance, and medical products industries. The main problems that those industries have to face are related to the poor weld quality due the improper selection of weld parameters. In the present work, 0.3 mm thick copper sheets were joined by USW varying the welding time, pressure, and vibration amplitude. The influence of the process variables on the characteristics of the joints and weld strength is investigated by using the analysis of variance. The results of the present work indicate that welding time is the main factor affecting the energy absorbed during the welding, followed by the pressure and amplitude. The shear strength, on the other hand, resulted mostly influenced by the amplitude, while the other parameters have a limited effect. Regardless the welding configuration adopted, most welds registered a failure load higher than the base material pointing out the feasibility of the USW process to join copper sheets.

Although different forms of renewable energy sources are in expansion, the oil and natural gas industry remains essential, maintaining its demand for more efficient methods for product transportation. The most productive and safe way is the flow through pipelines. However, pipeline usage directly involves several wear mechanisms, which contribute to pipeline degradation and, consequently, the need for repairs and maintenance shutdowns, implying in heavy financial impact in the entire industrial chain of supply. An economical and feasible solution to mitigate wear is to protect equipment with metallic coatings. Through this technique, engineers can keep the more noble—and expensive—metals only in regions where their chemical and mechanics proprieties are needed. Various processes may be industrially used for coating, presenting different levels of productivity, quality, and required investment. Among the arc welding processes, the most used for coating applications against wear and corrosion is the tungsten inert gas (TIG) process. The laser coating process, or laser metal deposition (LMD), a process concurrent to TIG, can apply such coatings with high precision and reproducibility, minimizing dilution, distortions, lack of fusion, and the formation of a large heat affected zones; however, results may vary. The present work evaluates two dilution-equivalent Inconel 625 coatings through rubber disk tribological testing, microhardness measurements, and worn surface analysis by scanning electron microscopy via energy dispersive x-ray analysis. Each coating was manufactured by one of the mentioned processes, LMD or TIG, with three replicates of each process to observe its repeatability. For the laser manufactured coating, microhardness values averaged to 247 HV, while TIG's average stayed at 218 HV. Volumetric loss due to wear testing behaved differently, with higher values about 16.3% more for TIG when compared to laser coating. The differences between microhardness values and volume losses are explained by crossing information from each coating's cross-section microscopy and worn surface, as well as each process parameterization and nature. In conclusion, LMD coating presented itself as the more efficient process; such a result, in parallel with the continuous advance in laser sources technology, makes a significant contribution to LMD consolidation as the pipeline coating process and a case study with a tribological comparison between two frequently applied processes.