Regarding porosity formation and gas content, choosing the appropriate shielding gas for laser welding is essential for achieving high-quality joints. Keyhole-induced porosity formation tendency and nitrogen content in SS 304 stainless steel welds were investigated based on the nitrogen content in shielding gases during fiber laser welding. Beads-on-plate autogenous welds were made at 5 kW continuous wave (CW) fiber laser in N₂ and Ar mixtures. Optical metallography, micro-focused X-ray, X-ray radiography, and high-speed images of the molten pool were used to investigate the porosity formation. In addition, a gas analyzer was used to study the weld metal nitrogen content. The results show that nitrogen significantly impacts the reduction of porosity in the melting zone and increases the dissolved nitrogen in the solidified weld metal, as using pure nitrogen leads to an increase in dissolved nitrogen by 36% higher than the nitrogen content in the base metal. In contrast, it has almost no significant effect on the keyhole mode.

The application of ultrasonic waves enhanced the wetting of alumina by Zn–Al filler alloy. Alumina ceramic was brazed to different metals such as Ti, Ni, Nb, Fe, and AISI 304 stainless steel using the Zn–5 mass-%Al brazing filler alloy. Different reaction products were formed at the alumina–metal interfaces, including solid solutions and intermetallic compounds. The alumina–Nb joint exhibited the highest bond strength value among the different couples, because Nb produces the lowest residual stress among the alumina–metal joints. The high mismatch in thermal expansion coefficient between the brazing filler and the AISI 304 stainless steel yielded the lowest bond strength among the joints.

Interfacial bonding highly affects the quality of bimetallic bearing materials, which primarily depend upon the surface quality of a solid metal substrate in liquid–solid compound casting. In many cases, an intermediate thin metallic layer is deposited on the solid substrate before depositing the liquid metal, which improves the interfacial bonding of the opposing materials. The present work aims to develop and optimize the tinning process of a solid carbon steel substrate after incorporating flux constituents with the tin powder. Five ratios of tin-to-flux—i.e., 1:1, 1:5, 1:10, 1:15, and 1:20—were used for tinning process of carbon steel solid substrate. Furthermore, the effect of volume ratios of liquid Al-based bearing alloy to solid steel substrate were also varied—i.e., 5:1, 6.5:1 and 8.5:1—to optimize the microstructural and mechanical performance, which were evaluated by interfacial microstructural investigation, bonding area determination, hardness and interfacial strength measurements. It was found that a tin-to-flux ratio of 1:10 offered the optimum performance in AlSn12Si4Cu1/steel bimetallic materials, showing a homogenous and continuous interfacial layer structure, while tinned steels using other percentages showed discontinuous and thin layers, as in 1:5 and 1:15, respectively. Furthermore, bimetallic interfacial bonding area and hardness increased by increasing the volume ratio of liquid Al alloy to solid steel substrate. A complete interface bonding area was achieved by using the volume ratio of liquid Al alloy to solid steel substrate of ≥8.5.