Multi-materials of metal-polymer and metal-composite hybrid structures (MMHSs) are highly demanded in several fields including land, air and sea transportation, infrastructure construction, and healthcare. The adoption of MMHSs in transportation industries represents a pivotal opportunity to reduce the product’s weight without compromising structural performance. This enables a dramatic reduction in fuel consumption for vehicles driven by internal combustion engines as well as an increase in fuel efficiency for electric vehicles. The main challenge for manufacturing MMHSs lies in the lack of robust joining solutions. Conventional joining processes, e.g., mechanical fastening and adhesive bonding involve several issues. Several emerging technologies have been developed for MMHSs’ manufacturing. Different from recently published review articles where the focus is only on specific categories of joining processes, this review is aimed at providing a broader and systematic view of the emerging opportunities for hybrid thin-walled structure manufacturing. The present review paper discusses the main limitations of conventional joining processes and describes the joining mechanisms, the main differences, advantages, and limitations of new joining processes. Three reference clusters were identified: fast mechanical joining processes, thermomechanical interlocking processes, and thermomechanical joining processes. This new classification is aimed at providing a compass to better orient within the broad horizon of new joining processes for MMHSs with an outlook for future trends.

A State-of-the-Art Review on Advanced Joining Processes for Metal-Composite and Metal-Polymer Hybrid Structures.

Various biomedical implants for prolonged usage in the human body have been created in recent years in a massive and steadily increasing number. Friction stir techniques are solid-state procedures used to improve the grain structure of biomaterials or to connect two workpieces while retaining their essential physical characteristics. This article primarily discusses the multidisciplinary topic of biocompatible implant surfaces from a microstructural, tribological, and mechanical strength perspective. It provides an overview of the most frequently used biomaterials, including metals such as steel, magnesium, and titanium, as well as polymers such as polyethylyne and polyether ether ketone (PEEK), their bulk and surface properties based on structural properties, and surface modification using various friction stir based techniques. These methods have the potential to substantially increase the lifespan of implants and their presence in human bodies. 

A review on biomedical implant materials and the effect of friction stir based techniques on their mechanical and tribological properties

In this paper, 12CrNi2 alloy steel samples were successfully fabricated by direct laser deposition (DLD) technology. The evolution of bainite in the DLD 12CrNi2 alloy steel process at different laser power of 1800 W, 2000 W and 2200 W and mechanical properties of as-deposited samples were investigated. The results showed that the middle-upper microstructure of the samples fabricated at different laser power transformed from lath bainite (LB) to granular bainite (GB) with increasing laser power. In addition, granular bainite was divided into blocky granular bainite (GB1) and lath-like granular bainite (GB2) according to different formation mechanisms, and the amount of GB1 increased and GB2 decreased in the range of laser power from 2000 W to 2200 W. No preferred texture was observed in the EBSD maps due to the complex heat flux direction which was resulted in the reciprocating scanning strategy. With the increase of laser power, the proportion of high-angle grain boundaries increased from 33.1% to 46.4% and that of low-angle grain boundaries decreased from 66.9% to 53.6%. The sample fabricated at 2000 W had the highest mean microhardness (331 HV0.2) and the best combination of ultimate tensile strength (757 MPa) and elongation (9.1%). However, the sample fabricated at 2200 W had the best impact toughness (aku = 100.0 J/cm2) because it contained a large amount of GB1 with dispersive and spherical-like island structures. This study provides the theoretical and experimental basis for the design of laser power and controllability of microstructure and properties in the DLD alloy steel process.

The evolution of bainite and mechanical properties of direct laser deposition 12CrNi2 alloy steel at different laser power

Process optimization to prepare T-joints of poly methyl methacrylate (PMMA) and AA5754 alloy by friction stir welding (FSW) was performed. Effects of processing parameters including tool rotational velocity, traverse speed, tilt angle and plunge depth (TP) were studied. The material flow and formation of interaction layer upon FSW were evaluated and the tensile strength and hardness of the joints were examined. It is shown that by controlling the heat input into stir zone through increasing the rotational velocity or decreasing travelling speed, less defects are formed while the thickness of the interaction layer increases. The optimum condition is attained at 1600 rpm/30 mm min−1 with a tool tilt angle of 2° and plunge depth of 0.2 mm. Under this condition, the joint strength would reach ~71% (50 MPa) of the base polymer. It has been found that the thickness of the interaction layer and formation of internal voids have a remarkable influence on the strength and hardness of the T-joints. The presented results could be useful for development of dissimilar FSW of metal/polymer joints.

An investigation on the dissimilar friction stir welding of T-joints between AA5754 aluminum alloy and poly(methyl methacrylate)

The composite coating reinforced with TiC and Al2O3 ceramic particles were fabricated on the Cr12MoV steel by laser cladding. The cross-section, microstructure, phase, microhardness and wear resistance of the composite coating were investigated by the optical microscope (OM), scanning electron microscope (SEM), transmission electron microscope (TEM), X-ray diffraction (XRD), Vickers microhardness tester and dry sliding wear testing machine, respectively. An obvious crack occurs in the coating when the content of the ceramic reinforcement is 15%. Composite coatings have good metallurgical bonding with the substrate when the content of the ceramic is less 15%. The phases of the composite coatings are composed of solid solutions (Ni–Cr–Fe and γ-(Fe,Ni)), chromic carbides (Cr3C2 and Cr2C), ferric carbide (Fe3C) and ceramics (TiC and Al2O3). The composite ceramics that Ti-rich alloy compound was coating unfused Al2O3 and TiC ceramics respectively were generated in the coating. A part of Ti element and C element, dissolved from the original TiC ceramic, precipitate from the matrix to form new TiC ceramic. These kinds of composite ceramic particles significantly improved the wear resistance of the coating via enhancing the bonding strength between the ceramic particles and the matrix.

The effect of TiC/Al2O3 composite ceramic reinforcement on tribological behavior of laser cladding Ni60 alloys coatings

Towards an explanation of liquid metal embrittlement cracking in resistance spot welding of dissimilar steels

Friction spot welding between porous TC4 titanium alloy and ultra high molecular weight polyethylene

Microstructure evolution of Fe-based nanostructured bainite coating by laser cladding

Effects of isothermal heat treatment on nanostructured bainite morphology and microstructures in laser cladded coatings

Effect of chemical segregation on nanobainitic transformation in laser cladded coatings

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