In the present investigation, thin sheets of stabilized and unstabilized ferritic stainless steel were welded in butt joint configuration using irradiation of a 1070 $\mathrm{n}\mathrm{m}$ fiber-laser. Using optical microscopy, the microstructural evolution upon alternating heat input was characterized. In addition to that, hardness and tensile tests were carried out on the specimens. Detailed focus was given to the intergranular corrosion properties, which were investigated on basis of the Strauss test with different times of exposure to the corrosive environment. Following these tests, the mechanical properties of the joints were characterized using tensile tests. A combination of the latter with an inspection by $\mathsf{\mu }$-CT analysis allows for the proposition of an intergranular corrosion rate with regard to the degradation of the joint strength.

High-speed friction stir welding (HSFSW) has emerged as a promising technique for improving the manufacturing efficiency of aluminum alloy structures by enabling faster welding while maintaining the quality of welded joints. This study investigates the mechanical properties and microstructural characteristics of AA 7020-T651 aluminum alloy joints welded using a novel multi-pin tool at high feed rates ranging from 2500 to 6000 mm/min under a constant rotational speed of 4000 rpm. Defect-free welds were successfully fabricated, as confirmed by metallographic analysis and micro-computed tomography (µ-CT). The multi-pin tool facilitated consistent material flow and heat distribution, which contributed to reliable joint formation across all feed rates. At the highest feed rate, the tensile strength reached 76% of the base material. A consistent softening in the nugget zone (NZ) was observed, and electron backscatter diffraction (EBSD) analysis showed a more than 70% grain size reduction in this zone, averaging ~3 µm, due to dynamic recrystallization. These findings underscore the suitability of HSFSW with multi-pin tools for high-speed industrial applications, offering enhanced productivity without compromising structural integrity.

Ferritic stainless steels are prone to localized corrosion phenomena such as pitting corrosion or intergranular corrosion, in particular when jointed by fusion welding processes. State-of-the-art techniques to avoid intergranular corrosion mainly consist of alternating alloy concepts or post-weld heat-treatments—all of which are associated with increased production costs. Hence, the present investigation seeks to introduce a novel approach for the inhibition of intergranular corrosion in ferritic stainless steel welds through the use of high-speed laser cladding. Here, vulnerable sites prone to intergranular corrosion along the weld seam area are coated with a chemically resistant alloy, whereby an overlap is achieved. Optical and electron microscopy as well as computer tomography and tensile tests reveal that the detrimental effects of intergranular corrosion in both stabilized and unstabilized ferritic stainless steel are substantially reduced. In addition to that, the effects of varying overlap widths on the identified corrosion phenomena are studied. Moreover, the resulting dilution and precipiation phenomena at the clad–sheet interface are thoroughly characterized by electron backscatter diffraction and energy dispersive X-ray spectroscopy, whereby interrelationships to corrosion resistance can be drawn. As a result of this investigation, the number of techniques for the inhibition of intergranular corrosion is enlarged, and substantial cost-saving potentials in the manufacturing industry are unlocked.

In this publication, an in-process quality assurance method for electron beam welding based on a structure-borne sound emission test for the detection of weld irregularities arising in the process is presented. For this purpose, different sheet materials, i.e., AISI 304, AZ31 and AlMg3, were welded in a butt-joint and the resulting process noises were recorded by means of two acoustic emission sensors specifically designed for structure-borne sound. During the welding experiments, typical irregularities, e.g. incidence points, pore lines and cracks, were deliberately induced. Subsequently, the recorded acoustic signals were examined with regard to defect-specific abnormalities. Various methods in the time and frequency domain as well as pre-trained machine learning models were used to analyze the acoustic emission data. The results show that the investigated irregularities can be identified and distinguished from other process emissions, eventually enabling a robust means of identification for weld seam irregularities and, thus, opening pathways towards cost-effective in-process quality control.

In this paper, the potential of directional ultrasonic wave superposition by moving sound generators for laser beam welding of high-strength steel alloys 1.5528 (22MnB5) is studied. Steel sheets of identical thickness and in form of tailored blanks were joined in butt joint configuration. The influences of the various excitation parameters of the moving sound generators on the ultrasonic coupling and their influence on the distribution of the AlSi coating components within the melting zone and the weld seam characteristics are investigated. Etched cross-sections, scanning electron microscopy, energy dispersive X-ray spectroscopy, and electron backscattering measurements were used as the investigation methods to determine the AlSi distribution in the weld as well as its microstructure. The results presented a series of experiments which show that a suitable superposition of ultrasonic waves by the moving sound generators lead to a more homogeneous distribution of AlSi particles in the melt as well as to a finer microstructure within the weld, which improves the mechanical–technological properties.