Welding of Advanced Materials: A Review on Process Adaptation for High-Strength Alloys and Composites

Abstract: Joining of highly engineered materials and especially high-strength alloys and composites is of great significance in the contemporary manufacturing process where high performance demands and material soundness are critical. The research looks into how welding processes have evolved to address the demands of the new high strength steels, titanium alloys and composite materials which are widely applied to the aerospace, automotive and the energy industries. These materials already have better qualities and are hard to weld because of such problems like thermal distortion, microstructural changes and losses in the mechanical properties during welding. The article discusses some of the welding techniques such as Friction Stir Welding (FSW), Electron Beam Welding (EBW) and Laser Welding and their merits and challenges. Some of the most critical issues commented on are the effects of heating on the microstructure/mechanical properties of welds, complications of joining unlike metals and interconnection of high-tech technologies like automation, artificial intelligence (AI), and computational modeling in strengthening welding process. The article goes further to explore some of the modes of non-destructive evaluation (NDE), which include ultrasonic testing and radiography inspection, which are fundamental in the quality check of a weld without compromising the material. With the demand of the high-performance materials rising, the necessity of the improved welding process and understanding of how the materials behave under the condition of the welding is crucial. The paper also cites research gaps in the practice and research fronts of welding, as well as what researchers are supposed to do in future to enhance further work in welding to the needs of high performance industries in the future.