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Handbooks in Advanced Manufacturing Advanced Welding and Deforming Series Editors-in-Chief J. PAULO DAVIM AND KAPIL GUPTA Edited by KAPIL GUPTA University of Johannesburg, South Africa J. PAULO DAVIM University of Aveiro, Portugal Elsevier Radarweg 29, PO Box 211, 1000 AE Amsterdam, Netherlands The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom 50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States Copyright © 2021 Elsevier Inc. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. 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Pazhayattil Designer: Victoria Pearson Esser Typeset by Thomson Digital Contributors Kumar Abhishek Department of Mechanical Engineering, Institute of Infrastructure Technology Research and Management (IITRAM), Ahmedabad, Gujarat, India Bappa Acherjee Production Engineering Department, Birla Institute of Technology, Mesra, Ranchi, Jharkhand, India Şenol Bayraktar Recep Tayyip Erdogan University, Faculty of Engineering and Architecture, Department of Mechanical Engineering, Rize, Turkey Udaya Bhat K Department of Metallurgical & Materials Engineering, NITK Surathkal, Srinivasnagar, Karnataka, India Devadas Bhat Panemangalore Department of Metallurgical & Materials Engineering, NITK Surathkal, Srinivasnagar, Karnataka, India Suma Bhat Department of Mechanical Engineering, SJEC, Vamanjuru, Mangaluru, Karnataka, India K.S Bindra Laser design and industrial applications division, Raja Ramanna Center for Advanced Technology, Indore, Madhya Pradesh; Homi Bhabha National Institute, BARC Training School Complex, Mumbai, Maharashtra, India Pierpaolo Carlone Department of Industrial Engineering, University of Salerno, Salerno, Italy Somnath Chattopadhyaya Department of Mechanical Engineering, Indian Institute of Technology (ISM) Dhanbad, Dhanbad, Jharkhand, India R. Comesaña CINTECX, Universidade de Vigo, LaserON Research group, School of Engineering, Vigo; Universidade de Vigo, Materials Engineering, Applied Mechanics and Construction Dpt., University of Vigo, Vigo, Spain Arash Darafsheh Department of Radiation Oncology, Washington University School of Medicine, St. Louis, MO, United States xvii xviii Contributors Manas Das Department of Mechanical Engineering, Indian Institute of Technology, Guwahati, Assam, India Amir Dehghanghadikolaei School of Mechanical, Industrial and Manufacturing Engineering, Oregon State University, Corvallis, OR, United States Dinbandhu Department of Mechanical Engineering, Institute of Infrastructure Technology Research and Management (IITRAM), Ahmedabad, Gujarat, India A.J. Gámez Department of Mechanical Engineering and Industrial Design, School of Engineering, University of Cadiz. Av. Universidad de Cádiz, Puerto Real, Cádiz, Spain L. García-Barrachina Department of Mechanical Engineering and Industrial Design, School of Engineering, University of Cadiz. Av. Universidad de Cádiz, Puerto Real, Cádiz, Spain Gozde Gecim Department of Chemical Engineering, Faculty of Engineering and Natural Sciences, Bursa Technical University, Bursa, Turkey Annamaria Gisario Department of Mechanical and Aerospace Engineering, Sapienza University of Rome, Rome, Italy S.M. Gorbatyuk National University of Science and Technology «MISIS», Moscow, Russia Ali Pa¸sa Hekimog˘lu Recep Tayyip Erdogan University, Faculty of Engineering and Architecture, Department of Mechanical Engineering, Rize, Turkey N. Rajesh Jesudoss Hynes Department of Mechanical Engineering, Mepco Schlenk Engineering College (Autonomous), Sivakasi, Tamil Nadu, India Ayse Kalemtas Department of Metallurgical and Materials Engineering, Faculty of Engineering and Natural Sciences, Bursa Technical University, Bursa, Turkey Hariharan Krishnaswamy Department of Mechanical Engineering, Indian Institute of Technology Madras, Chennai, Tamil Nadu, India Contributors xix Manoj Kumar Singh Composite Design and Manufacturing Lab, School of Engineering, Indian Institute of Technology Mandi, Mandi, Himachal Pradesh, India Chandan Kumar Department of Mechanical Engineering, Indian Institute of Technology, Guwahati, Assam, India R. Kumar Faculty of Mechanical Engineering, Eritrea Institute of Technology, Eritea Rajeev Kumar Composite Design and Manufacturing Lab, School of Engineering, Indian Institute of Technology Mandi, Mandi, Himachal Pradesh, India Hossein Lavvafi Department of Radiation Oncology, William Kahlert Cancer Center, Westminster, MD, United States F. Lusquiños CINTECX, Universidade de Vigo, LaserON Research group, School of Engineering, Vigo, Spain G. Madhusudhan Reddy Defence Metallurgical Research Laboratory, Kanchanbagh, Hyderabad, Telangana, India P. Mastanaiah Defence Research and Development Laboratory, Kanchanbagh, Hyderabad, Telangana, India Mehrshad Mehrpouya Faculty of Engineering Technology, University of Twente, Enschede, The Netherlands Kush P. Mehta Department of Mechanical Engineering, School of Technology, Pandit Deendayal Petroleum University, Gandhinagar, Gujarat, India; Advanced Manufacturing and Materials Research Group, Department of Mechanical Engineering, School of Engineering, Aalto University, Espoo, Finland N.A. Chichenev National University of Science and Technology «MISIS», Moscow, Russia Maria Ntsoaki Mathabathe Council of Scientific Industrial Research, Materials Science and Manufacturing, Manufacturing cluster, Advanced Materials Engineering, Pretoria, South Africa Sharath P C Department of Metallurgical Engineering, Jain University, Bengaluru, Karnataka, India xx Contributors Amogelang Sylvester Bolokang Council of Scientific Industrial Research, Materials Science and Manufacturing, Manufacturing cluster, Advanced Materials Engineering, Pretoria, South Africa Himanshu Pathak Composite Design and Manufacturing Lab, School of Engineering, Indian Institute of Technology Mandi, Mandi, Himachal Pradesh, India C.P. Paul Laser design and industrial applications division, Raja Ramanna Center for Advanced Technology, Indore, Madhya Pradesh, India; Homi Bhabha National Institute, BARC Training School Complex, Mumbai, Maharashtra, India J. Pou CINTECX, Universidade de Vigo, LaserON Research group, School of Engineering, Vigo, Spain Vishalkumar Prajapati Department of Mechanical Engineering, Institute of Infrastructure Technology Research and Management (IITRAM), Ahmedabad, Gujarat, India Dinesh W. Rathod Department of Mechanical Engineering, Thapar Institute of Engineering and Technology, Thapar Technology Campus, Patiala, Punjab, India A. Riveiro CINTECX, Universidade de Vigo, LaserON Research group, School of Engineering, Vigo; Universidade de Vigo, Materials Engineering, Applied Mechanics and Construction Dpt., University of Vigo, Vigo, Spain Pankaj Sahlot Department of Mechanical Engineering, School of Technology, Pandit Deendayal Petroleum University, Gandhinagar, Gujarat, India R. Sankaranarayanan Department of Mechanical Engineering, Mepco Schlenk Engineering College (Autonomous), Sivakasi, Tamil Nadu, India Sachindra Shankar Department of Mechanical Engineering, Indian Institute of Technology (ISM) Dhanbad, Dhanbad, Jharkhand, India Abhay Sharma KU Leuven, Faculty of Engineering Technology, Department of Materials Engineering, Campus De Nayer, Jan Pieter de Nayerlaan, Sint-Katelijne-Waver, Belgium Contributors xxi Shivraman Thapliyal Mechanical Engineering Department, National Institute of Technology, Warangal, Telangana, India J. del Val CINTECX, Universidade de Vigo, LaserON Research group, School of Engineering, Vigo; Centro Universitario de la Defensa, Escuela Naval Militar, Marín, Spain P. Shenbaga Velu Department of Mechanical Engineering, PSR Engineering College, Sivakasi, Tamil Nadu, India Nishant Verma Composite Design and Manufacturing Lab, School of Engineering, Indian Institute of Technology Mandi, Mandi, Himachal Pradesh, India Pedro Vilaça Advanced Manufacturing and Materials Research Group, Department of Mechanical Engineering, School of Engineering, Aalto University, Espoo, Finland Jay J. Vora Department of Mechanical Engineering, School of Technology (SOT), Pandit Deendayal Petroleum University (PDPU), Gandhinagar, Gujarat, India D. Wallerstein CINTECX, Universidade de Vigo, LaserON Research group, School of Engineering, Vigo, Spain Sunny Zafar Composite Design and Manufacturing Lab, School of Engineering, Indian Institute of Technology Mandi, Mandi, Himachal Pradesh, India Series Foreword Dear Readers, This series of handbooks on advanced manufacturing covers four major areas, namely, advanced machining and finishing, advanced welding and deforming, additive manufacturing, and sustainable manufacturing. The series aims to not only present the advancements in various manufacturing technologies, but also provides a fundamental and detailed understanding about them. It encompasses a wide range of manufacturing technologies with their mechanisms, working principles, salient features, applications, and research, development, and innovations in there. Fundamental research, latest developments, and case studies conducted by international experi- enced researchers, engineers, managers, and professors are mainly presented. Handbook 1 on advanced machining and finishing majorly covers advanced machining of difficult-to-machine materials; hybrid, high speed, and micro- machining; and burnishing, laser surface texturing, and advanced thermal energy-based finishing processes. Handbook 2 on advanced welding and deforming covers ultrasonic welding, laser welding, and hybrid welding type advanced joining processes and also describes advanced forming techniques such as microwave processing, equal channel angular pressing, and energy assisted forming, etc. Handbook 3 additive manufacturing sheds light on 3D and 4D printing, rapid prototyping, laser-based additive manufacturing, advanced materials and post-processing in additive manufacturing. Handbook 4 on sustainable manufacturing presents advancements, results of experimen- tal research, and case studies on sustainability interventions in production and industrial technologies. We hope that this series of handbooks would be a good source of knowledge and encourage researchers and scientists to conduct research, developments, and innovations to establish these fields further. J. Paulo Davim and Kapil Gupta xxiii Preface Joining and forming are two major groups of manufacturing processes. Limitations of traditional processes have been overcome by technological advancements that derived advanced welding and deforming processes to attain the special requirements related to quality, cost, and sustainability. This handbook covers such technological advancements in a wide range of welding and deforming processes. Basic to advanced level knowledge along with the latest research in this area as well as possible avenues of future research are also highlighted to encourage the researchers. The handbook consists of a total of 20 selected chapters on advances in welding and deforming processes. It starts with Chapter 1 where joining of metals and plastics using ultrasonic welding, is discussed. Laser welding is introduced in Chapter 2 along with a special focus on fiber laser welding of titanium alloys. Chapter 3 discusses advancements in gas metal arc welding process via modifications in short circuiting transfer mode. A comprehensive analysis of gas tungsten arc welding with a case of nickel alloys is presented in Chapter 4. Recent developments in laser welding of aluminum alloys are highlighted in Chapter 5. Friction stir welding tool design for joining lightweight materials is given in Chapter 6. Chapter 7 sheds light on magnetic pulse welding. Chapter 8 provides insights on laser welding of NiTi shape memory alloys. Aspects of hybrid welding technologies are presented in Chapter 9. A wide range of optimization techniques and their implementation and effectiveness for enhancement of weldability in case of various welding processes are discussed in Chapter 10. Chapter 11 presents joining by laser cladding. Chapter 12 introduces friction stir processing and a case of fabrication of nanocomposites. A unique microwave- assisted polymer composite fabrication process is detailed in Chapter 13. Chapter 14 presents equal channel angular pressing as a modern deforming technique. Fundamental and advances in longitudinal rolling are described in Chapter 15. Energy assisted forming and its applications are focused on Chapter 16. Chapter 17 discusses multi directional forging as an advanced deforming technique for severe plastic deformation. Analysis of superplastic forming process is presented in Chapter 18. Casting techniques for aluminum and machinability analysis of cast parts are covered in Chapter 19. Chapter 20 sheds light on forming of ceramic microspheres for various specialized applications. xxv xxvi Preface We hope that this handbook would be a good source of knowledge and information for researchers, engineers, technical experts, and special- ists working in the area of welding and deforming processes. We sincerely acknowledge Elsevier for this opportunity and their professional support. Finally, we would like to thank all contributors for their time and efforts. Kapil Gupta and J. Paulo Davim January 2021