crystals

Editorial
Welding and Joining of Metallic Materials: Microstructure and
Mechanical Properties
Ali Khalfallah 1, * , Mahmoud Moradi 2 and Reza Beygi 3,4

1 CEMMPRE, Department of Mechanical Engineering, University of Coimbra, Rua Luís Reis Santos,
3030-788 Coimbra, Portugal
2 Faculty of Arts, Science and Technology, University of Northampton, Northampton NN1 5PH, UK;
[email protected]
3 Institute of Science and Innovation in Mechanical and Industrial Engineering (INEGI), Rua Dr. Roberto Frias,
4200-465 Porto, Portugal; [email protected]
4 Department of Materials Engineering and Metallurgy, Faculty of Engineering, Arak University,
Arak 38156-8-8349, Iran
* Correspondence: [email protected]; Tel.: +351-933-411-080

The study of welding and joining technologies for metallic materials has long been
fundamental to advancing numerous industries, including aerospace, automotive, and
energy [1,2]. These techniques not only enable the fabrication of complex components but
also serve as a critical factor in the mechanical performance and reliability of structures [3,4].
A thorough understanding of the microstructure and mechanical properties of welded joints
is essential for improving joint strength, durability [5], and overall material performance,
particularly in demanding environments [6,7].
In recent years, technological advancements in welding processes [8] and the devel-
opment of new materials [9] have prompted an increasing need for in-depth research to
optimize these techniques [10,11]. In this context, the Special Issue “Welding and Joining of
Metallic Materials: Microstructure and Mechanical Properties” brings together a collection of
ten innovative research articles. These contributions focus on elucidating the relationships
between welding parameters, the resulting microstructures, and the mechanical properties
of both similar and dissimilar material joints.
This Special Issue aims to bridge the gap between fundamental scientific research
and practical industrial applications, addressing the challenges posed by modern welding
Citation: Khalfallah, A.; Moradi, M.;
Beygi, R. Welding and Joining of
processes. By exploring advanced welding techniques, investigating the microstructure of
Metallic Materials: Microstructure
various alloys, and evaluating the performance of welded joints under different conditions,
and Mechanical Properties. Crystals
the published articles provide valuable insights into how these processes can be refined
2024, 14, 839. https://doi.org/ and adapted for enhanced performance.
10.3390/cryst14100839 The ten contributions can be broadly categorized into three key research themes. This
Editorial discusses their scientific significance, offering readers a cohesive overview of the
Received: 20 September 2024
advancements in welding and joining technologies presented in this Special Issue.
Accepted: 25 September 2024
Published: 27 September 2024 1. Process optimization and advanced welding techniques
Three papers explore the optimization of welding processes and the development of
advanced techniques to enhance weld quality, energy efficiency, and mechanical properties.
Copyright: © 2024 by the authors. - Contribution (1): Effect of Laser Heat Input on the Microstructures and Low-Cycle
Licensee MDPI, Basel, Switzerland. Fatigue Properties of Ti60 Laser Welded Joints [12]. This study investigates the effects
This article is an open access article of varying laser heat input on the microstructure and mechanical properties of Ti60
distributed under the terms and titanium alloy welded joints. The results reveal that different heat inputs significantly
conditions of the Creative Commons affect the morphology of the weld zone (WZ), reducing porosity in Y-type WZs, which
Attribution (CC BY) license (https:// enhances low-cycle fatigue resistance. The research contributes valuable insights into
creativecommons.org/licenses/by/ optimizing laser welding parameters for improved weld quality.
4.0/).

Crystals 2024, 14, 839. https://doi.org/10.3390/cryst14100839 https://www.mdpi.com/journal/crystals

Crystals 2024, 14, 839 2 of 5

- Contribution (2): Effect of Exothermic Additions in Core Filler on Arc Stability and
Microstructure during Self-Shielded Flux-Cored Arc Welding (FCAW) [13]. This paper
explores the use of exothermic additives in flux-cored arc welding to enhance arc
stability and deposition efficiency. By optimizing the CuO/Al and CuO/C ratios in
the core filler, this study demonstrates how filler composition influences arc stability
and welding current, providing a route to more energy-efficient welding processes.
The mathematical models developed in this work further enhance the prediction of
welding parameters.
- Contribution (3): Particle Swarm Method for Optimization of ATIG Welding Process
to Join Mild Steel to 316L Stainless Steel [14]. This article presents the optimization
of activating tungsten inert gas (ATIG) welding using particle swarm optimization
(PSO) to join mild steel to 316L stainless steel. The findings show that the optimized
flux composition significantly improves weld penetration and hardness, without
compromising the mechanical properties of the joint. This study offers a promising
solution for improving the quality of dissimilar material welds.
2. Microstructure and mechanical properties of welded joints
Four contributions focus on the intricate relationship between welding-induced mi-
crostructural changes and their effects on the mechanical properties of welded joints,
shedding light on material behavior under different conditions.
- Contribution (4): Microstructural Optimization of Sn-58Bi Low-Temperature Solder
Fabricated by Intense Pulsed Light (IPL) Irradiation [15]. This paper introduces IPL
soldering as a novel method for optimizing the microstructure of Sn-58Bi solder. By
regulating the irradiation time, this study demonstrates how the solder microstructure
evolves from immature to refined, impacting mechanical properties such as hardness.
This technique offers potential for improving low-temperature soldering processes in
electronics manufacturing.
- Contribution (5): Experimental and Computational Study of Microhardness Evolu-
tion in the HAZ for Al–Cu–Li Alloys [16]. This paper focuses on simulating the
microhardness evolution in the heat-affected zone (HAZ) of Al-Cu-Li alloy welds. By
replicating the thermal cycles experienced during welding, the research explores the
dissolution and coarsening of strengthening precipitates in the HAZ, contributing to a
deeper understanding of how welding affects the mechanical properties of advanced
aluminum alloys.
- Contribution (6): Heat-Affected Zone Microstructural Study via Coupled Numer-
ical/Physical Simulation in Welded Superduplex Stainless Steels [17]. This work
introduces a hybrid approach, combining physical and numerical simulations to in-
vestigate the HAZ of super-duplex stainless steel (SDSS). The authors successfully
simulate thermal cycles using a Gleeble® machine and compare the results with actual
welds, providing valuable insights into how thermal management during welding
can preserve the microstructural balance between ferrite and austenite, essential for
maintaining corrosion resistance and mechanical integrity.
- Contribution (7): Structure–Property Correlation between Friction-Welded Work-
Hardenable Al-4.9Mg Alloy Joints [18]. The research evaluates the microstructure and
mechanical properties of AA5083 H116 joints produced by rotary friction welding.
This study reveals that grain refinement in the dynamically recrystallized zone (DRZ)
enhances joint strength, although slight reductions in ductility are observed. These
findings are particularly relevant for applications in aerospace and automotive sectors
where high-strength aluminum alloys are frequently used.
3. Welding of dissimilar materials
Three papers address the complexities and challenges involved in joining dissimilar
materials, focusing on optimizing welding parameters and techniques to produce strong
and high-performance joints.
Crystals 2024, 14, 839 3 of 5

- Contribution (8): Study of the Microstructure and Mechanical Property Relation-

ships of Gas Metal Arc Welded Dissimilar Protection 600T, DP450, and S275JR Steel
Joints [19]. This paper addresses the challenges of welding dissimilar steels through
gas metal arc welding (GMAW). The findings reveal that the mechanical proper-
ties of the joints, such as tensile strength and hardness, can be optimized by se-
lecting appropriate welding parameters. In particular, DP450/S275JR dissimilar
joints exhibit the highest joint efficiency, making this technique highly applicable to
industrial processes.
- Contribution (9): Effect of Microchemistry Elements in Relation to Laser Welding
Parameters on the Morphology of 304 Stainless Steel Welds Using Response Surface
Methodology [20]. This study investigates the effect of sulfur content on the weld
bead morphology of AISI 304 stainless steel by using laser welding. The response
surface methodology (RSM) analysis reveals how small variations in sulfur content
and welding parameters, such as power and focus point, can significantly influence
weld pool formation and mechanical performance.
- Contribution (10): Investigation of the Microstructure and Mechanical Properties in
Friction Stir Welded Dissimilar Aluminium Alloy Joints via Sampling Direction [21].
This paper investigates the microstructure and mechanical properties of dissimilar
aluminum alloys joined by friction stir welding (FSW), with an emphasis on the effect
of sampling direction. This work shows that the longitudinal joints exhibit higher
tensile strength and elongation compared to the transverse joints, providing critical
insights into the optimization of FSW for dissimilar aluminum alloys.
In essence, this Special Issue on Welding and Joining of Metallic Materials: Microstructure
and Mechanical Properties brings together cutting-edge research that spans advanced welding
techniques, microstructural analysis, and the challenges of welding dissimilar materials.
This Special Issue reflects the incredible effort and dedication of the authors who
shared their valuable findings. We are deeply grateful to each contributor for their insights,
and to the peer reviewers for their hard work in upholding the quality of these papers. A
big thank you also goes to everyone else involved in making this possible.
The contributions to this Special Issue are listed as follows:
Contribution (1)—Zhang, Q.; Ren, L.; Lei, X.; Yang, J.; Zhang, K.; Zhang, J. Effect of Laser
Heat Input on the Microstructures and Low-Cycle Fatigue Properties of Ti60 Laser Welded
Joints. Crystals 2024, 14, 677.
Contribution (2)—Lozynskyi, V.; Trembach, B.; Katinas, E.; Sadovyi, K.; Krbata, M.; Balenko,
O.; Krasnoshapka, I.; Rebrova, O.; Knyazev, S.; Kabatskyi, O.; et al. Effect of Exothermic
Additions in Core Filler on Arc Stability and Microstructure during Self-Shielded, Flux-
Cored Arc Welding. Crystals 2024, 14, 335.
Contribution (3)—Touileb, K.; Djoudjou, R.; Ouis, A.; Hedhibi, A.C.; Boubaker, S.; Ahmed,
M.M.Z. Particle Swarm Method for Optimization of ATIG Welding Process to Joint Mild
Steel to 316L Stainless Steel. Crystals 2023, 13, 1377.
Contribution (4)—Go, H.; Noh, T.; Jung, S.-B.; Sohn, Y. Microstructural Optimization of
Sn-58Bi Low-Temperature Solder Fabricated by Intense Pulsed Light (IPL) Irradiation.
Crystals 2024, 14, 465. https://doi.org/10.3390/cryst14050465.
Contribution (5)—Maritsa, S.; Deligiannis, S.; Tsakiridis, P.E.; Zervaki, A.D. Experimental
and Computational Study of Microhardness Evolution in the HAZ for Al–Cu–Li Alloys.
Crystals 2024, 14, 246.
Contribution (6)—da Silva, L.O.P.; Lima, T.N.; Júnior, F.M.d.S.; Callegari, B.; Folle, L.F.;
Coelho, R.S. Heat-Affected Zone Microstructural Study via Coupled Numerical/Physical
Simulation in Welded Superduplex Stainless Steels. Crystals 2024, 14, 204.
Contribution (7)—Mahajan, A.M.; Krishna, K.V.; Quamar, M.J.; Rehman, A.U.; Bandi, B.;
Babu, N.K. Structure–Property Correlation between Friction-Welded Work and Hardened
Al-4.9Mg Alloy Joints. Crystals 2023, 13, 1119.
Crystals 2024, 14, 839 4 of 5

Contribution (8)—Elmas, M.; Koçar, O.; Anaç, N. Study of the Microstructure and Mechani-
cal Property Relationships of Gas Metal Arc Welded Dissimilar Protection 600T, DP450 and
S275JR Steel Joints. Crystals 2024, 14, 477.
Contribution (9)—Touileb, K.; Attia, E.; Djoudjou, R.; Hedhibi, A.C.; Benselama, A.; Ibrahim,
A.; Ahmed, M.M.Z. Effect of Microchemistry Elements in Relation of Laser Welding Param-
eters on the Morphology 304 Stainless Steel Welds Using Response Surface Methodology.
Crystals 2023, 13, 1138.
Contribution (10)—Mabuwa, S.; Msomi, V. Investigation of the Microstructure and Mechan-
ical Properties in Friction Stir Welded Dissimilar Aluminium Alloy Joints via Sampling
Direction. Crystals 2023, 13, 1108.
As welding technologies evolve and new materials are introduced, the interplay be-
tween microstructure and mechanical properties will continue to be a focal point of research.
We believe this collection of articles offers a clear snapshot of the latest breakthroughs and
makes a significant contribution to advancing our knowledge in this vital area. We hope
the findings presented in this reprint will inspire further innovations in the field of welding
and joining.

Funding: This study received no external funding.

Conflicts of Interest: The authors declare no conflicts of interest.

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Aluminium Alloy Joints via Sampling Direction. Crystals 2023, 13, 1108. [CrossRef]

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