A novel approach in the field of narrow gap laser welding produces superior weld joint quality, especially the configuration of weld toe, which has a positive effect on fatigue life.

Stress corrosion cracking is an insidious form of damage that can occur when a susceptible metal is subjected to a tensile stress in a specific environment. To relieve tensile stresses at welded joints, postweld heat treatment can be helpful in reducing the susceptibility of carbon steel fabrications to SCC. When planning to use stainless steels in chloride-containing environments, it is advisable to select alloys that have been specifically developed to resist stress chloride cracking such as ferritic-austenitic (duplex) alloys, low-carbon ferritic alloys, and 6% Mo austenitic alloys or to select high-nickel alloys.

This article discusses the development of a new metallographic technique to identify defects in aluminum alloy joints produced by friction stir welding. This method won the Jacquet-Lucas Award for Excellence in Metallography at the International Metallographic Contest held during MS&T in Pittsburgh, October 2017.

Linear friction welding (LFW) is a solid-state process capable of joining noncircular parts by oscillating one part under load to create frictional heating. From joining railroad rails to producing strong aluminum-to-steel joints, recent advancements in LFW technology are reducing equipment costs and expanding potential uses.

A new solid-state joining process for medical guidewire applications increases joint strength, provides superior bending properties, and does not require tertiary metals or ferrules. This process may be a superior method to create joints between dissimilar metals such as stainless steel and Nitinol.

A new welding process known as hybrid induction arc welding (HIAW) or high deposition arc welding (HiDep) uses a hybrid approach to reduce—or even eliminate—weld distortion and greatly increase productivity. Operating directly in front of the arc welding torch, a portable induction coil heats the surfaces of the weld to, or near, the melting point. Heat generated by the welding arc is primarily used to melt the welding wire. This novel process operates at speeds two to four times faster than conventional arc welding and substantially reduces weld distortion.

Advanced instrumentation combined with effective test procedures gives manufacturers an edge in measuring and analyzing welds.

A new design and welding process may extend the life of furnace rolls in hot-dip coating lines, which often fail in less than one year. This article is a case study of analysis of a failed furnace roll that led to a proposed improved design to extend component life.

Mechanical spot-joining methods such as self-pierce riveting (SPR) enable the use of different material combinations in vehicle design. The SPR technique provides a robust joint that often outperforms clinching and spot welding under both static and fatigue conditions, while providing fast cycle times and zero waste.

Self-pierce riveting is a candidate for joining magnesium alloy sheet, extrusions, and castings in automotive applications. This article evaluates the fatigue performance of magnesium lap joints held together by laser-assisted self-piercing rivets (SPR) with and without the addition of adhesives.

Several key materials processes and techniques positively impact weight reduction and reusability of parts designed for travel to the moon, Mars, and beyond. This article addresses how advances in technologies such as additive manufacturing, friction stir welding, and surface analysis, can help further enhance design and fabrication of space systems.

Typical vehicles contain more than 3000 spot welds, and failure parameters for these welds must be accurately predicted in crash simulations. A testing protocol developed at EWI for the purpose of creating spot weld failure parameters has been used since 2010 to establish these parameters for automotive manufacturers for a range of steel and aluminum stack-ups. Crash simulations in full-vehicle models show that the failure parameters created by this method are accurate for predicting the initiation of spot weld failure by comparing results with experimental data.

Metallographic examination and optical emission spectroscopy shed light on the origin of a lampshade found in the aftermath of Hurricane Katrina. The steels used for the ring and wire in the frame are typical of those made prior to WWII and the fabrication processes appear to be of a similar timeframe. Tassels on the lampshade were determined to be a more recent alteration and the fabric was found to be cow skin parchment based on DNA testing.

Beyond weight savings, aluminum products offer corrosion resistance, weldability, and ease of maintenance for a wide range of marine vessels. Aluminum was recognized as a promising material for marine construction from the early days of the industry. The development of 5xxx alloys and large production capacity made aluminum use more technically and economically possible beginning in the 1950s. The variety of aluminum vessels ranges from small fishing boats and fast ferry catamarans to cruise ships and military vessels. All benefit from aluminum's relatively light weight, low maintenance costs, and easy repairability. Other benefits of using aluminum in marine applications include formability, corrosion resistance, and availability in various product forms.

Through a series of case studies, the benefits of micro x-ray fluorescence (XRF) over traditional XRF are demonstrated in the power generation industry for informing weld procedures, identifying root cause, and providing materials or component specifications.

Successful part brazing relies on proper joint design, part cleanliness, and correct fixturing of part assemblies. Routine furnace maintenance allows repeatable, quality brazing results over time. This article describes aluminum brazing processes and process control considerations.

In the quest to improve the reliability of partial penetration welding validation, advanced ultrasonic testing techniques have replaced other less accurate methods. This case study compares weld penetration inspection results from phased array ultrasonic testing and the total focusing method in a rib-to-deck assembly on the top part of an orthotropic steel bridge deck.

Recent advances in high velocity oxygen fuel torches in the form of miniaturization, joining, automation, and digitization are increasing the application opportunities for this thermal spray coating technology.

Active metal brazing played a key role in the development and fabrication of a modified beam target for particle-physics experiments conducted by Fermilab. The new target consists of a titanium tube filled with stacked graphite fins that were bonded in place by means of active metal brazing. This article describes the vacuum process and the methods used to evaluate the brazed titanium-graphite joints.

Additive manufacturing (AM) continues to make significant technology advancements and attract widespread interest in industry, academia, and the general media. However, the technology is likely still a decade away from attaining meaningful implementation in industry and has yet to find adoption in large-scale or partcritical manufacturing operations, such as airframe structural component production. As a bridge technology that takes advantage of existing manufacturing methods while AM is being fully developed, near-net manufacturing is a promising alternative. Near-net fills the gap between classic subtractive manufacturing and AM, and it may be accurately described in terms of grain size.