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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
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The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom
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Publisher (other than as may be noted herein).

Notices
Knowledge and best practice in this field are constantly changing. As new research and experience
broaden our understanding, changes in research methods, professional practices, or medical
treatment may become necessary.

Practitioners and researchers must always rely on their own experience and knowledge in evaluating
and using any information, methods, compounds, or experiments described herein. In using such
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parties for whom they have a professional responsibility.

To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume
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negligence or otherwise, or from any use or operation of any methods, products, instructions, or
ideas contained in the material herein.

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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 Paşa Hekimoğlu

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 ma-
jor areas, namely, advanced machining and finishing, advanced welding and
deforming, additive manufacturing, and sustainable manufacturing. The se-
ries 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 de-
forming 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, ad-
vanced 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 technologi-
cal 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 re-
search 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 weld-
ing 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 technolo-
gies 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 pro-
cessing 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 alu-
minum 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
CHAPTER 1

Ultrasonic welding—a modern

welding technology for metals
and plastics
Shivraman Thapliyal
Mechanical Engineering Department, National Institute of Technology, Warangal, Telangana, India

1 Introduction
Ultrasonic welding (USW) is the solid-state welding process in which joint
between metals, metal-plastic, and plastics is developed by high-frequency
ultrasonic vibrations [1–3]. The faying surfaces are clamped under the ap-
plication of the static force and subjected to ultrasonic vibration. The high-
frequency vibration causes the relative motion between the surfaces, which
causes disruption of asperities by simultaneous plastic deformation. The
frictional heating, along with the heat generated during plastic deforma-
tion, is sufficient to produce the joint between the surfaces.
Initially, ultrasonic vibrations were applied to the resistance spot welds
to improve the grain structure of the welds. Later, it was realized that weld
was developed between faying surfaces with the sole application of ultra-
sonic vibrations only. The first report on the implementation of ultrasonic
vibration as the welding source was published in 1950 [1]. Initially, this pro-
cess was restricted to thin sheets, foil bonding, and tube sealing [2]. How-
ever, the current demands and advancement in the process made it feasible
for the welding of thick sheet [3]. The USW has extensively been used in
microelectronics, automotive, medical, and aerospace industries [4,5]. This
welding used to join various alloys of copper, aluminum, steel, and nickel.
The ultrasonic welding process can also be used for the joining of different
dissimilar metals, plastics, and metal-plastic combinations.

2 Ultrasonic welding system and process variation

USW system consists of an electronic power supply that converts line
power into high frequency and high voltage power for the transducer. The
transducer converts the electrical energy into high-frequency mechanical
Advanced Welding and Deforming Copyright © 2021 Elsevier Inc.
http://dx.doi.org/10.1016/B978-0-12-822049-8.00001-3 All rights reserved. 1
2 Advanced Welding and Deforming

vibration ranging from 15 to 300 kHz [6]. These high-frequency vibra-

tions are transferred to the workpiece by the sonotrode. The workpiece is
held firmly between the sonotrode tip and anvil that provides the necessary
clamping force, and the anvil act as the supporting system for the workpiece.
The lateral drive system and wedge reed system are the two types of USW
systems. The wedge reed system was designed and patented in 1960, which
uses a vertical vibrating member termed as a reed to which vibrations are
supplied from a coupler transducer assembly perpendicular to the reed. The
clamping forces are applied on the weld plates through the reed. The vi-
brations produce a shear motion at the interface region, as the vibration
directions are parallel to the weld interface. However, in the lateral drive
system, the vibrations are transferred directly to the welding horn from
the booster-transducer-sonotrode assembly. The booster that is mounting
the total stack of the tooling system directly applies the downward force
(Fig. 1.1A,B). Nowadays, fully programmable USW systems are available, in
which the process parameters are controlled by the microprocessors. USW
uses a closed-loop feedback system, which regulates a process variable to the
desired value with the help of the feedback system.
An example of 3 kW and with a frequency of 20 kHz wedge is shown
in Fig. 1.2.These USW systems have different variants that can produce dif-
ferent types of weld joints, that is, spot, line, ring, and continuous.

2.1 Spot welding

The joint between two overlapping material is developed at a small spot by
the introduction of vibratory energy into the workpiece held between so-
notrode and the anvil. The vibrations are applied parallel to the joint line or
weld interface. The welding can be achieved in less than 1.5 s, but the weld
time is dependent on the material type, thickness, and power unit.

2.2 Line welding

This welding is a variation of spot welding in which a continuous line weld
is achieved by the help of linear sonotrode tip vibrating parallel to the weld
interface. A weld of length nearly equal 6 in. can be obtained in a single
weld cycle.

2.3 Continuous seam weld

These welds are obtained when a rotating disked shaped ultrasonic horn is
rotated and traversed over the workpiece supported on the anvil. This setup
can be used to join foils up to 0.15 mm thickness.
 Ultrasonic welding—a modern welding technology for metals and plastics 3

Figure 1.1 Schematic of (A) wedge reed and (B) lateral drive ultrasonic welding system.
4 Advanced Welding and Deforming

Figure 1.2 Photograph of (A) wedge reed ultrasonic metal welder with (B) sonotrode tip,
(C) weld tip [7]. (With kind permission from Elsevier).

2.4 Torsion/ring weld

The torsion/ring welds are produced by imparting twisting or torsional
motion to the horn. This system uses two transducers vibrating longitudi-
nally which are 180 degrees out of phase with each other and thus provid-
ing torsional motion at the weld interface. This system is used for sealing
of the container carrying liquid and powder propellant with the thin foil
sheets. Ring weld of diameter 50 mm has been successfully produced for
aluminum and copper foils.

3 Ultrasonic welding process mechanism and working

In USW, when two surfaces are brought in contact by static clamping
force, immediately, the asperities present on the surface come in contact
(Fig. 1.3A) [2]. When the ultrasonic vibrations are applied on the top part
which in contact with sonotrode tends to vibrate in the direction of ap-
plied vibration resulting in sliding, deformation of the asperities along with
the disruption of metal oxides present at faying surfaces, which increases
the area of contact and coefficient of friction (Fig. 1.3B) [5,7].This increase
in the area causes direct metal-to-metal contact, and the formation of mi-
cro welds due to deformation. Increasing the duration of ultrasonic vibra-
tion causes significant heat generation due to friction and plastic deforma-
tion, which causes material softening and ease the material flow near the
 Ultrasonic welding—a modern welding technology for metals and plastics 5

Figure 1.3 Schematic depicting the working operations of the ultrasonic welding
process.

joint line (Fig. 1.3C). Additionally, the acoustic vibrations are absorbed in
the dislocation, which also increases the material flow. As the welding cycle
terminates, the contact area and adjacent area are completely deformed
with recrystallized grains. The metallic bonding in the weld zone under
the sonotrode tip is visible (Fig. 1.3D). The metallic bonding achieved
due to welding is a solid-state, which implies no melting and fusion of
the workpiece. The temperature measurement studies on USW suggested
that the temperature rises rapidly in the initial stage of welding, and then
it remains stable for the remaining cycle. Although a significant rise in the
temperature is observed initially, it remains below the melting point of the
metals/alloys [8].
6 Advanced Welding and Deforming

In USW, the different phenomenon occurs, that is, (1) surface film
disruption, (2) plastic deformation, (3) recrystallization, and (4) diffusion
across the interface. However, the diffusion and recrystallization phe-
nomenon were ruled out after investigating the low-frequency USW of
aluminum and copper alloys [9–11]. Therefore, the dominant phenom-
enon for the solid-state joining of material in USW is slip and plastic
deformation [12].
The weld interface is subjected to non-uniform deformation through-
out the structure. Visually a weld zone exhibits shear bands and swirls, and
thermomechanically affect zone (TMAZ) consists of the convoluted wave-
like pattern. This convoluted bonding line appears in the weld region also
when the energy input increases beyond the optimum range due to the
combined action of shear and normal force.

4 Ultrasonic welding process parameters

The quality of the ultrasonic weld depends on the system and material pa-
rameters (Fig. 1.4). The system parameters will dominate the weld quality
of the joint. However, the material parameters govern the weldability of
materials. The various parameters affecting the USW process are explained
briefly in this section [6,13].

Figure 1.4 Ultrasonic welding process parameters.

 Ultrasonic welding—a modern welding technology for metals and plastics 7

Table 1.1 Showing operating range of USW frequency for various material systems.
Frequency range (kHz) Material system

15–20 Plastic
20–60 Metal
120–300 Electronic micro bonding system

4.1 Frequency
In USW, the transducer operates at different ranges of frequencies varying
from 15 to 300 kHz. The selection of frequencies is based on the material
to be joined (Table 1.1). The high-frequency equipment offers lesser noise,
better part protection, and small tooling size, but it comprises the power
capability. During welding of different material classes, the system operates
at fixed frequencies. Hence, the role of frequency in the weld quality is not
considered.

4.2 Amplitude
The welding amplitude is the critical parameter that governs the soundness
of the weld joint.The amplitude during welding is small, ranging from 10 to
50 µm at the weld region. The amplitude controlling can be related to the
power input, and sometimes it can be controlled by the separate feedback
system depending upon the welding systems. The selection of the optimum
amplitude for the welding of the material is based on other factors like
power, welding time, and clamping force.

4.3 Static clamping force

It is the force applied on the workpiece by the welding tip and sonotrode to
hold the part firmly together and develop the intimate contact between the
parts to be joined. It is one of the critical factors, which depends upon the
material, thickness of the material, and weld size. It ranges from 10 to 103 N,
and there exists an optimum range of clamping force for a set of parameters
that defines the strength of the weld.

4.4 Welding power, time, and energy

The welding power (P), time (t), and energy (U) are not independent vari-
ables [Eq. (1.1)]. The weld can be obtained for peak power after a substan-
tial amount of time (s) or weld cycle. The weld energy will be the area
under the power v/s time curve (Fig. 1.5). The power transmitted to the
8 Advanced Welding and Deforming

Figure 1.5 Power curve for ultrasonic welding.

transducer from the electrical systems is transferred to the weld in terms of

ultrasonic power.
U =P× t (1.1)

The actual power obtained at the weld zone will depend upon (1) the
efficiency of the electro-mechanical conversion system, (2) losses in the
bulk material, and at the interfaces of the transducer-booster-sonotrode sys-
tem, and (3) energy dissipated by the weld to surroundings, that is, work-
piece and anvil.

4.5 Material
The properties of materials like hardness, ductility, and oxide formation ten-
dency to govern the weld quality of the ultrasonic weld. The hard materials
exhibit poor weldability due to their higher resistance to the plastic defor-
mation during welding.The ductile materials support smooth material flow
during welding and hence are easier to weld. Oxide layer formation on the
metal surface causes entrapment of oxides in the form of a thin layer near
the weld interface due to which the weld quality compromises.

4.6 Tooling
The tooling refers to sonotrode tip and anvil that contact the top and bot-
tom portion of the weld, respectively. The tooling serves the purpose of
 Ultrasonic welding—a modern welding technology for metals and plastics 9

transmission of ultrasonic vibration to the weld interface and supports the

workpiece firmly. The primary design modifications are performed on the
sonotrode, but the anvil face is kept flat most of the time. The tool tips are
specially designed and treated to improve gripping and wear resistance.

5 Ultrasonic welding of metals and alloys

USW is used for the joining of various similar and dissimilar metal, plastic,
and metal-plastic systems. The bond formed in between these combina-
tions exhibits various features, which explain the joining mechanism and
mechanical properties of the weld. This section will elaborate on the weld-
ing metallurgy, and weldability aspect of various material systems joined by
USW.

5.1 Welding of similar metals and alloys

USW is one of the most preferred joining techniques for the aluminum
alloys because in conventional fusion welding of aluminum alloys, the melt-
ing and solidification of weld results in the hot cracking, liquation cracking,
and welding defects which compromise with the mechanical properties.
However, these defects were not encountered in the solid-state welding
(USW) process because it does not involve melting. An ultrasonically weld-
ed (USWed) aluminum joints consist of three zones (1) weld zone, (2) weld
affected zone, and (3) compression zone. The weld affected zone and com-
pression zone exhibits deformed and elongated grains. However, the grains
in the weld zone are refined and difficult to resolve, suggesting the dynamic
recrystallization [14].
Haddadi and colleagues [15] categorized the different deformation zone
as (1) forging zone near contact point of sonotrode tip and sheet, (2) shear
zone at the mid-section of the upper sheet, (3) ultrafine grain structure near
the weld interface, (4) shear bands and swirl, and (5) convoluted wave-like
pattern in TMAZ of Al 6111-T4 ultrasonic weldments (Fig. 1.6A,B). The
fine grain structure in the USWed is attributed to severe plastic deforma-
tion and dynamic recrystallization [16–19]. The formation of shear bands,
swirl, and convoluted patterns depends upon the welding parameters, spe-
cifically welding energy. At low energies or shorter weld time, the presence
of these features is rare due to non-uniform contact pressure. However,
increasing the weld energies or weld time results in a significant amount of
plastic deformation and frictional heating, which causes the formation of
swirls and convoluted wave-like patterns [20,21]. Additionally, the extreme
10 Advanced Welding and Deforming

Figure 1.6 Optical macro images of ultrasonically welded Al 6111 developed with a
pressure of 40MPa and weld energies and time of (A) 150 J/0.06 s and (B) 750 J/0.3 s [21].
(With kind permission from Elsevier).

deformation causes the rotation of the micro bond region due to cyclic
strain within the local regions at the interface, which also plays an essential
role in swirl development.
The microstructure of dissimilar aluminum alloys, that is, Al 6022 and
Al 7075 weld, revealed that grain refinement in the top plate and grain
coarsening in the bottom plates with significant diffusion of Zn in the alu-
minum.The refine grain structure is attributed to severe plastic deformation
and frictional heating, and the grain coarsening in the bottom plate is due
to limited plastic deformation [22]. Therefore, it can be concluded that the
alloying elements play an essential role in controlling the grain size in the
weld zone.
The ultrasonic welded pure copper exhibited fine grain structure as
compared to the base metal. However, increasing the welding energy causes
grain coarsening in the bonded region (dotted region) (Fig. 1.7A,B) ow-
ing to excessive strain and heat accumulation at the bond zone [23]. Ward
and colleagues [24] also observed the grain coarsening and second phase
precipitation at the weld zone of Cu foils at higher weld time owing to
significant frictional heating.
The presence of nano-particles interlayer between the Cu–Cu joints
improves the joint quality owing to enhanced frictional coefficient and
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Title: Landesverein Sächsischer Heimatschutz — Mitteilungen

Band XIII, Heft 5-6
Monatsschrift für Heimatschutz, Volkskunde und
Denkmalpflege

Author: Landesverein Sächsischer Heimatschutz

Release date: October 28, 2023 [eBook #71976]

Language: German

Original publication: Dresden: Landesverein Sächsischer

Heimatschutz, 1924

Credits: The Online Distributed Proofreading Team at

https://www.pgdp.net

*** START OF THE PROJECT GUTENBERG EBOOK

LANDESVEREIN SÄCHSISCHER HEIMATSCHUTZ —
MITTEILUNGEN BAND XIII, HEFT 5-6 ***
 Anmerkungen zur Transkription
Das Original ist in Fraktur gesetzt. Im Original gesperrter ist so ausgezeichnet.
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 Landesverein Sächsischer Heimatschutz
Dresden

Mitteilungen
Heft
5 bis 6
Monatsschrift für Heimatschutz, Volkskunde und Denkmalpflege
Band XIII
Inhalt: Weinberghäuser in der Lößnitz und den Meißner
Bergen – Herrensitze der Lößnitz – Die Lößnitz und die
Dresdner Heide – Der Untergang des Weinbaus – Die
Rotalge Hildenbrandia rivularis (Liebm.) Bréb., ein
ausgestorbenes (?) Naturdenkmal Sachsens – Vom
neuen Weinbau

Einzelpreis dieses Heftes 2 Goldmark

Geschäftsstelle: Dresden-A., Schießgasse 24
Postscheckkonto: Leipzig 13 987,
Dresden 15 835 Stadtgirokasse Dresden 610
Bankkonto: Commerz- und Privatbank, Abteilung Pirnaischer Platz,
Dresden
Bassenge & Fritzsche, Dresden
Dresden 1924
 An unsere werten Mitglieder!
Wir bitten wiederholt um Einsendung der Monatsbeiträge (1 Mark,
Ermäßigung bis auf 50 Pfg. stillschweigend bei wirtschaftlich
Schwachen gestattet).
Auch diesem Hefte liegt ein Anmeldezettel bei, der uns neue
Mitglieder zuführen soll. Wir bitten recht eifrig zu werben. Dank im
voraus.

Mit deutschem Gruß

Landesverein Sächsischer Heimatschutz

Band XIII, Heft 5/6 1924

Die Mitteilungen des Vereins werden in Bänden zu 12 Nummern

herausgegeben
Abgeschlossen am 1. Juni 1924
 Weinberghäuser in der Lößnitz und
den Meißner Bergen
Von Reg.-Baurat Dr. Paul Goldhardt
Wenn wir von den Elbhöhen unterhalb Dresdens, etwa vom
Standpunkte des Spitzhauses, ins weite lichte Land hinausblicken
und, die tektonischen Massen der herüber- und hinübergrüßenden
stolzen Ufer abwägend, das Bild des breit und majestätisch
dahinziehenden Elbstromes in uns aufnehmen, werden die zu
unseren Füßen sich ausbreitenden Niederungen gar bald unsere
Aufmerksamkeit auf sich ziehen. Welch ein unübersehbares
Häusermeer! Kauert sich doch von Dresden bis nahe an Meißen,
zwischen Gärten und Alleen eingebettet, ein Häuschen neben das
andere; kleine Giebelfenster blitzen unter roten und dunkelblauen
Dächern auf, in nicht endenwollender Zahl sind menschliche
Siedlungen und Arbeitsstätten zwischen Strom und Berg verstreut.
Vor solcher Übervölkerung der heimatlichen Erde erschrickt man,
und leise mischt sich die ständig mit uns wandelnde Sorge um das
Los unseres gequälten Volkes in die fröhliche Wanderstimmung. Und
doch, wer die trauten heimatlichen Täler und Höhen ins Herz
geschlossen hat, den werden die üppigen Gärten und die von weiter
Sicht so simpel daliegenden und in der Nähe gesehen so kompliziert
auf die modernen Bedürfnisse der Menschen eingestellten
Siedlungen auch mit Zuversicht erfüllen, denn sie versinnbildlichen
ihm mit eindringlicher Macht die unüberwindliche Kraft des Volkes,
die auch durch jahrzehntelange Unterdrückung hindurch zum Lichte
strebt. Sind doch all diese Gehöfte und Werkstätten innerhalb
weniger Jahrzehnte aus dem Erdboden geschossen und haben eine
vollkommene Umwertung der Landschaft hervorgerufen.
Der Wanderer, der gegen Anfang oder um die Mitte des
verflossenen Jahrhunderts die Elbhöhen erstieg, konnte noch
landschaftliche Bildungen von vollendeter Reinheit und Lieblichkeit
bewundern, von denen der heutige Zustand kaum noch einen
matten Abglanz widerspiegelt. Wem ständen, wenn er sich jener
Zeiten erinnert, nicht Ludwig Richtersche Radierungen vor Augen,
auf denen die Poesie der Weinkultur verherrlicht wurde? Sie sind für
immer dahin, jene anmutigen Zeiten der Bergeinsamkeit, die Tage
farbenreicher ländlicher Feste, der wandernden Gesellen und
versonnenen Zecher.
Und nur unsre Phantasie kann uns von der Unberührtheit der
damaligen Lößnitzberge eine Vorstellung geben, als dort noch ein
weiter großer Garten Gottes war, umzäunt und durchschnitten von
tausend Steinmäuerchen und Treppchen, die sich bergab und
bergauf zwischen saftigem Weinlaub, knorrigen Nußbäumen und
uralten Linden dahinzogen, als dieses ganze sonnige Berg- und
Hügelland samt der vorgelagerten breiten Talsohle, über und über in
Grün getaucht, noch frei war von städtischen Ansiedlungen, und als
dieses ewige Grün nur an ganz wenigen Stellen und wohlberechnet
durchsetzt war von den fröhlichen roten Ziegeldächern und weißen
Mauerflächen der kleinen Winzerhäuschen und Weingüter. Uns
bleibt, wenn wir jene alten schönen Zeiten neuerleben wollen, nichts
übrig, als sehenden Auges umherzuschweifen und den alten trauten
Zeugen einer verklungenen Kultur nachzuforschen. Mit der Freude
des Entdeckers werden wir zwischen Rebstöcken, abgebrochenen
Alleen und verfallenen Mäuerchen diese malerischen Häuschen eins
nach dem anderen auffinden und mit steigendem Entzücken
feststellen, welch große künstlerische Einheit sie umfaßt, wie immer
und immer wieder das trauliche Walmdach wiederkehrt, wie
hinsichtlich der Stellung des Häuschens zur Straße und zum
Weinberg und der künstlerischen Verflechtung von Haus, Garten und
Berg überall dieselbe ordnende Hand tätig gewesen zu sein scheint.
Stand doch das Winzerhaus wie das vornehme Landhaus immer
unten im Tal und überließ das sonnige Berggelände dem Rebstock,
der sich bis zum Bergkamm hinaufzog. Dort aber an höchster Stelle
entstanden allerliebste Wachthäuschen, denn zur Zeit der reifenden
Trauben war dort Aufsicht geboten. Welche anmutige Lösungen
fanden unsere Vorfahren hierfür, welche entzückenden Türmchen
und Pavillons krönen allerorts die Weinbergsgrundstücke und
erzählen von der fröhlichen Schaffenslust der Bewohner und von
ihrem feinen und natürlichen Gefühl für bauliche Aufgaben!
Wenden wir uns kurz dem geschichtlichen Ursprung und
Werdegang der Weinbergsbauten in der Lößnitz zu, so ist zunächst
festzustellen, daß aus der Zeit vor 1550 nichts Bemerkenswertes
erhalten ist, und daß die überwiegende Zahl der baulichen Anlagen
vom Anfang des achtzehnten bis zum Anfang des neunzehnten
Jahrhunderts errichtet wurde. Da aber die Rebenkultur in den
Elbbergen viel älteren Ursprungs ist, glaubt man sie doch, auf
gewisse Urkunden fußend, bis ins zwölfte Jahrhundert, also in die
Zeit der Neubesiedlung des Landes durch die Deutschen,
zurückverfolgen zu können, so scheint die Geschichte des
sächsischen Weinbaues nun schon dreiviertel Jahrtausend mit der
Entwicklung unserer engeren Heimat verknüpft zu sein. Im frühen
Mittelalter, als Sorben und Deutsche um den fruchtbaren Boden
gerungen haben, wurde der Weinbau von den Klöstern und
Kirchenfürsten gefördert, und gewiß war Meißen auch der
Ausgangspunkt dieser wichtigen Kulturerscheinung, deuten doch
gewisse altüberlieferte Orts- und Gebäudebezeichnungen, so z. B.
die der Bischofspresse in Zitzschewig, auf diese Tatsache hin.
Jahrhundertelang war die kleine Rebenstadt das Herz des Landes,
bis sie infolge von dessen politischer Umbildung das Zepter an
Dresden abtreten mußte. Der Weinbau aber hat indessen nicht
aufgehört, im Wirtschaftsleben des Landes eine große Rolle zu
spielen, und wir können annehmen, daß die Rebenkultur im Verlaufe
der Jahrhunderte von ausschlaggebender Bedeutung für die
landschaftliche Gestaltung des Elbgebirges und für sein bauliches
Bild gewesen ist.
Von Dresden aus übernahmen dann die weltlichen Fürsten die
Fürsorge für den Weinbau, höfische und städtische Kultur ist es, die
von jetzt ab im Gefolge des Weinbaues in die Berge vordringt. Es
sind die reichsten und schönsten Blätter der sächsischen
Kulturgeschichte, die sich uns nun eröffnen, die Zeit des
farbenprächtigen Barockes, jener wundervollen Stilgebundenheit, die
dem gesamten Leben der damaligen Zeit Glanz und Weihe verlieh.
August der Starke und seine schönheitstrunkene Zeit! Die Strenge
des Hofzeremoniells löste ein um so freieres, ungebundeneres
Landleben aus; erschöpft von den gesundheitraubenden Hoffesten
und überdrüssig des Staubes der bewegten Stadt, bestiegen die
zierlichen Perückendamen und höflichen Kavaliere die breiten
Staatskutschen, und hinaus in die weinumrankten Berghäuschen
ging die fröhliche Fahrt, anmutigen Schäferspielen und neuen
Intrigen entgegen. Und nun beginnt ein herzerquickender Wetteifer
der baulustigen Stadtherren, immer schönere Weingüter zu
ersinnen, immer lieblichere Gebilde aus Stein und Dachwerk
zwischen malerischen Bergtreppen und schnurgeraden Alleen
hervorzuzaubern. Freilich die Namen der Künstler sind verschollen.
Sei es drum, war doch das ganze schönheitsgierige Jahrhundert
kunstbegabt, war doch jeder ein Meister. Waren auch viele der
damals entstandenen Weinbergshäuser kleineren Umfanges und
von bescheidenem Äußeren, so erscheinen sie uns, die wir der
baulichen Verwilderung der letzten Jahrzehnte müde sind und gierig
dem Schatz unserer guten alten einheimischen Kunst nachforschen,
doch alle wie Zeugen aus einer besseren Zeit, in der anständige
künstlerische Durchbildung des Hauses noch eine
selbstverständliche Forderung war.
Als Auftakte der Lößnitzbaukunst sind in erster Linie das launige
mit reicher den Wein verherrlichender Plastik geschmückte Portal im
Garten der Hellerschänke, sodann das an der Baumwiese gelegene
Fachwerkhaus (Abb. 1) zu nennen. Es soll der Gräfin Cosel als
Zuflucht gedient haben und zeigt im Innern noch einige Reste
reicherer Raumdurchbildung, worauf ja schon der prächtige
Fachwerkserker, der in unserer Gegend selten vorkommt, hindeutet.
Zu diesen auf die Lößnitz vorbereitenden Bauwerken gehört aber
auch der gut umrissene Gasthof »Pfeifer« in Wahnsdorf und das alte
Weingut am Wilden Mann, Döbelner Straße 108 (Abb. 2).
 Abb. 1 Fachwerkhaus an der Baumwiese
Aufnahme von Josef Ostermaier, Dresden-Blasewitz

Inzwischen gelangen wir in die Oberlößnitz und stoßen an der

Wettinstraße auf ein rechtes Märchenhaus: das Kiauhaus (Abb. 3),
versteckt hinter einem dichten Schleier knorriger und
hochaufstrebender Zweige und gemütlich umgürtet von einer breit
geschwungenen Steinmauer. Sollen wir die Entstehung dieses
seltsamen Baumindividuums dem Zufall zuschreiben oder hat feiner
Gestaltungssinn diese wundervolle Einheit zwischen Menschenwerk
und Naturgebilde geschaffen? Man kann wohl nur letzteres
annehmen.
 Aufnahme von P. Georg Schäfer, Dresden
Abb. 2 Weingut in Dresden, Döbelner Straße
Noch schlichter und ländlicher wirkt Haus Breitig in der
Kronprinzstraße mit seinem dunklen Fachwerk und hellen
Putzfeldern, es steht so fest verankert mit dem Boden und innig
angeschmiegt an die Naturumgebung (Abb. 4).
 Aufnahme von J. Pfeiffer, Oberlößnitz
Abb. 3 Kiauhaus, Oberlößnitz, Wettinstraße
 Abb. 4 Haus Breitig, Oberlößnitz, Kronprinzstraße

An der Ecke der Nizza- und Sophienstraße treffen wir auf einen
besonders rassigen Bau, (Abb. 5), ohne jede schmückende Zierat ist
er in strenger Gesetzmäßigkeit aufgebaut, das obere Geschoß ist
kräftig zurückgesetzt und mittels breiter Dachschräge mit dem
Unterbau verbunden.
 Abb. 5 Haus Ecke Nizza- und Sophienstraße, Oberlößnitz
Wem daran gelegen ist, zunächst die architektonisch reicher
behandelten Bauten aufzusuchen, dem wird man empfehlen, in
allererster Linie das reizende kleine Bennoschlößchen zu
besichtigen (Abb. 6). Es liegt noch weiter ab vom Bergfuß an der
mittleren Bergstraße und ist einer der ältesten Zeugen der hier
behandelten Hausgattung. Da die Weinpresse später angebaut
wurde, ist es nicht ganz sicher, ob das aus der Zeit um 1600
stammende Häuschen schon von seiner Errichtung an als
Weinbergshaus gedient hat, es ist dies aber anzunehmen.
Bewundernswert ist der trotz bescheidener Größe mit
Renaissanceformen ausdrucksvoll gegliederte Gesamtumriß,
nebenbei erwähnt ein Beweis dafür, daß Bauwerke kleineren
Umfangs nicht immer auf reichere Formen verzichten müssen. Im
Innern freilich erinnert wenig mehr an alte Lebensfreude und
Weinlaunigkeit.
 Aufnahme von J. Pfeiffer, Oberlößnitz
Abb. 6 Bennoschlößchen, Oberlößnitz
 Abb. 7 Haus in der Bennostraße, Oberlößnitz

Das auf Abb. 7 gezeigte Haus in der Bennostraße zeichnet sich

durch gute Stellung in der Straße und durch einen interessanten
Dachgiebel aus, wie wenig an Zutaten bedurfte es doch, diesen
schlichten Häusern Eigenart und Reiz zu verleihen.
 Abb. 8 Haus Sorgenfrei, Oberlößnitz
Aufnahme von J. Ostermaier, Dresden-Blasewitz

Ein charakteristischer Vertreter der Lößnitzbaukunst aber ist

»Sorgenfrei«, an der Schulstraße gelegen, in den Jahren 1786 bis
1789 herrschaftlich und breit angelegt (Abb. 8). Das
Hauptwohnhaus, von stattlicher Baumallee zugänglich und mit
breitem mittleren Dachaufbau im Stil des Empire, Fruchtgehängen,
Vasen und Türmchen, alles in allem eine bauliche Erscheinung von
soviel Anmut und Fröhlichkeit und soviel bodenständiger Eigenart,
daß man sich nur mit wahrer Freude an seinen reizenden Eindruck
erinnert. Man lernt aus solchen Werken, daß man Bauten nicht
erzeichnen, sondern plastisch erfassen soll, wir sind freilich heute
weit entfernt von der Naivität, die hierzu erforderlich ist.