International Journal of Machine Tools & Manufacture最新文献_第4页

A novel computational approach using receptance coupling substructure analysis for prediction of tool tip dynamics in industrial machining applications 基于接受耦合子结构分析的新型计算方法在工业加工中的应用

IF 14 1区工程技术 Q1 ENGINEERING, MANUFACTURING

International Journal of Machine Tools & Manufacture

Pub Date : 2025-05-23 DOI: 10.1016/j.ijmachtools.2025.104296

Jesus David Chaux, Patxi X. Aristimuño Osoro, Pedro J. Arrazola

引用次数: 0

Inducing electrochemical discharges on insulating surfaces for damage-free electrochemical jet machining of glass 在绝缘表面诱导电化学放电，用于玻璃的无损伤电化学喷射加工

IF 14 1区工程技术 Q1 ENGINEERING, MANUFACTURING

International Journal of Machine Tools & Manufacture

Pub Date : 2025-05-20 DOI: 10.1016/j.ijmachtools.2025.104293

Genglin Zhu , Hexin Li , Wenjun Lu , Sanjun Liu , Weidong Liu , Yonghua Zhao

A key limitation of electrochemical jet machining (EJM) is its inability to process insulating materials. While electrochemical discharge machining (ECDM) can handle such materials, its contact-based nature often causes thermal damage. Additionally, the challenge of initiating electrochemical discharges on the insulating workpiece, rather than on the tool electrode, remains unresolved. This study presents a new mechanism for directly inducing electrochemical discharges on insulating surfaces through the controlled interplay of electro- and hydrodynamic fields. For the first time, we demonstrate damage-free machining of insulating materials using an electrolyte jet, in a new process termed jet-electrochemical discharge machining (Jet-ECDM). This is achieved by generating electrochemical discharges at the jet-impingement zone on the insulating workpiece surface, with the gas evolved at the nozzle electrode acting as a dielectric. The spatiotemporal dynamics of discharges, including location, frequency, and intensity, are analyzed and shown to critically influence machining results. High-speed imaging visualizes the gas bubble behaviors, while simulation reveals how discharges are focused onto a localized machining area through concentrated electric fields and gas distribution. Key process parameters, including voltage, working gap, and electrolyte flow rate, are identified for effective process control. Thermocouple measurements show a discharge-induced average temperature rise of ∼160 °C at the machining site. Unlike conventional ECDM, Jet-ECDM's non-contact approach avoids thermal damage, enabling stress-free, purely chemical material removal. This is validated by machining microfeatures in quartz glass, achieving superior surface finishes (∼Ra 50 nm) and a damage-free subsurface. This research extends the material applicability of EJM to insulating materials and introduces a novel method for stress-free machining of glass and ceramics using electrochemical discharges.

电化学喷射加工（EJM）的一个关键限制是它不能加工绝缘材料。虽然电化学放电加工（ECDM）可以处理这类材料，但其基于接触的性质往往会导致热损伤。此外，在绝缘工件上启动电化学放电的挑战，而不是在工具电极上，仍然没有解决。本研究提出了一种通过控制电场和水动力场的相互作用在绝缘表面上直接诱导电化学放电的新机制。我们首次展示了使用电解液射流对绝缘材料进行无损伤加工，这是一种称为射流-电化学放电加工（jet- ecdm）的新工艺。这是通过在绝缘工件表面的射流撞击区产生电化学放电来实现的，在喷嘴电极处产生的气体充当电介质。分析了放电的时空动态，包括位置、频率和强度，并表明放电对加工结果有重要影响。高速成像可视化气泡的行为，而模拟揭示了放电如何通过集中的电场和气体分布集中在局部加工区域。确定关键工艺参数，包括电压、工作间隙和电解质流速，以进行有效的过程控制。热电偶测量显示，在加工现场，放电引起的平均温升为~ 160°C。与传统ECDM不同，Jet-ECDM的非接触式方法避免了热损伤，实现了无应力、纯化学材料的去除。通过加工石英玻璃的微特征，实现了卓越的表面光洁度（~ Ra 50 nm）和无损伤的亚表面，验证了这一点。本研究将EJM的材料适用性扩展到绝缘材料，并介绍了一种利用电化学放电无应力加工玻璃和陶瓷的新方法。

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引用次数: 0

Ultrafast phase transformation and strengthening mechanisms in alloys induced by femtosecond laser shock: a novel strategy for intermetallic control 飞秒激光冲击诱导合金的超快相变和强化机制：一种新的金属间控制策略

IF 14 1区工程技术 Q1 ENGINEERING, MANUFACTURING

International Journal of Machine Tools & Manufacture

Pub Date : 2025-05-17 DOI: 10.1016/j.ijmachtools.2025.104292

Zhiyuan Liu , Wenmin Tang , Feng Pan , Xueran Deng , Fei Fan , Jingjing Yang , Cheng Lei , Sheng Liu , Qiao Xu , Du Wang

This study proposes a novel alloy-strengthening strategy enabled by femtosecond laser shock peening (FLSP), which utilizes ultrahigh peak shock pressures exceeding the intrinsic bond rupture strength of metallic bonds to achieve atomic-level microstructural modification. In contrast to conventional nanosecond laser shock peening (NLSP), FLSP induces a distinct strengthening mechanism through the dynamic fragmentation of intermetallic phases and the controllable precipitation of nanoscale strengthening phases. Through integrating a synergistic experimental investigation with molecular dynamics (MD) simulation, we establish a generalized pressure–dependent phase transformation framework, identifying critical thresholds of shock pressure required to initiate atomic bond rupture and subsequent phase evolution. This framework enables precise tuning of energy input to promote the formation of nanoscale strengthening phases while suppressing undesirable microscale precipitates. Compared to NLSP, FLSP demonstrates superior efficacy in microstructure refinement capabilities, enabling synergistic strengthening through grain refinement, dislocation multiplication, and pressure-mediated phase transformation. Notably, the discovered pressure–sensitive phase evolution behavior provides a transferable paradigm for microstructural design and performance optimization across a wide range of metallic systems. This work advances the fundamental understanding of laser–matter interactions under extreme conditions and offers a physics-informed pathway for the design of high-performance structural materials through targeted laser parameter engineering.

本研究提出了一种新型的飞秒激光冲击强化（FLSP）合金强化策略，该策略利用超过金属键固有键断裂强度的超高峰值冲击压力来实现原子级微结构改性。与传统的纳秒激光冲击强化（NLSP）相比，FLSP通过金属间相的动态破碎和纳米级强化相的可控析出诱导出独特的强化机制。通过将协同实验研究与分子动力学（MD）模拟相结合，我们建立了一个广义的压力相关相变框架，确定了启动原子键断裂和随后的相演化所需的冲击压力的临界阈值。该框架能够精确调整能量输入，以促进纳米级强化相的形成，同时抑制不需要的微尺度沉淀。与NLSP相比，FLSP在微观组织细化能力方面表现出更高的效率，可以通过晶粒细化、位错倍增和压力介导的相变实现协同强化。值得注意的是，所发现的压敏相演化行为为广泛的金属体系的微结构设计和性能优化提供了可转移的范例。这项工作促进了对极端条件下激光与物质相互作用的基本理解，并通过定向激光参数工程为高性能结构材料的设计提供了一条物理信息途径。

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引用次数: 0

Suppression of hot cracking in Ni-based single-crystal superalloys fabricated by laser directed energy deposition through thermal cycle regulation 热循环调控抑制激光定向能沉积镍基单晶高温合金热裂

IF 14 1区工程技术 Q1 ENGINEERING, MANUFACTURING

International Journal of Machine Tools & Manufacture

Pub Date : 2025-05-01 DOI: 10.1016/j.ijmachtools.2025.104283

Yan Zeng, Boyuan Guan, Tianyu Yuan, Huitao Chen, Lei Li

The fabrication of Ni-based single-crystal (SX) superalloys through laser directed energy deposition (L-DED) is hindered by the high susceptibility of SX structures to hot cracking. Therefore, achieving crack-free SX superalloys during L-DED is crucial for advancing the application of this technology in SX turbine blade repair. Based on solidification shrinkage and solid-bridging theory, this study systematically investigated the formation mechanisms of hot cracks in a multi-pass multi-layer DD6 SX prepared by L-DED through microstructure characterisation and coupled thermal-mechanical simulations. The results demonstrate that the initiation and propagation of hot cracks are governed by the overlapping characteristics at the inter-pass and interlayer regions, which influence the formation of liquid films and localisation of the stress-strain concentration. Furthermore, the results revealed that the formation of stray grains and hot cracking mutually amplified each other. To address these challenges, a novel strategy for hot crack suppression is to optimise the dwell time at the inter-pass and interlayer regions to regulate the dendrite growth and elemental segregation. Consequently, a three-pass five-layer Ni-based single-crystal sample with a width of 2–3 mm was successfully prepared, which was free of cracks. Moreover, the hot crack suppression method was applied to single-pass thin-wall deposition, achieving a single-crystal structure with height exceeding 10 mm and a proportion of over 95 %. The repair quality surpassed the requirements for single-crystal blade repair. This study provides new insights into the thermal-mechanical mechanisms underlying hot cracking and establishes a scientific framework for mitigating the cracks in L-DED DD6 SX, thereby advancing their applicability in high-end component repair.

激光定向能沉积法制备镍基单晶（SX）高温合金，阻碍了SX结构对热裂的敏感性。因此，在L-DED过程中实现SX高温合金无裂纹对于推进该技术在SX涡轮叶片修复中的应用至关重要。基于凝固收缩和固体桥接理论，通过显微组织表征和热-力学耦合模拟，系统研究了L-DED法制备多道次多层DD6 SX的热裂纹形成机制。结果表明：热裂纹的萌生和扩展受通道间和层间区域的重叠特征控制，这影响了液膜的形成和应力-应变集中的局部化。结果表明，杂散晶粒的形成与热裂是相互放大的。为了解决这些挑战，一种新的热裂纹抑制策略是优化在通道间和层间区域的停留时间，以调节枝晶生长和元素偏析。因此，成功制备了三道五层镍基单晶样品，宽度为2-3 mm，无裂纹。将热裂纹抑制方法应用于单道次薄壁沉积，获得了高度超过10 mm，占比超过95 %的单晶结构。修复质量超过单晶刀片修复要求。本研究为热裂纹的热力学机制提供了新的见解，并为L-DED DD6 SX的裂纹缓解建立了科学的框架，从而提高了其在高端部件修复中的适用性。

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引用次数: 0

Grindability and microstructural effect of nickel-based superalloys in magnetic field-assisted ultra-precision grinding 磁场辅助超精密磨削镍基高温合金的可磨削性及显微组织效应

IF 14 1区工程技术 Q1 ENGINEERING, MANUFACTURING

International Journal of Machine Tools & Manufacture

Pub Date : 2025-05-01 DOI: 10.1016/j.ijmachtools.2025.104284

Te Zhao, Tengfei Yin, Dongbo Wu, Yi Tan, Denghui Li, Waisze Yip, Suet To

The nickel-based superalloy Inconel 718 is essential in the aerospace and automotive industries due to its exceptional mechanical strength, fatigue resistance, and resistance to corrosion and oxidation. However, machining nickel-based alloys poses significant challenges in ultra-precision grinding (UPG), resulting in excessive grinding wheel vibration and poor surface quality. This study introduces an innovative magnetic field-assisted ultra-precision grinding (MFAUPG) technology, representing an advancement in the application of magnetic fields to assist grinding processes. A theoretical model was developed that links magnetic fields to grinding dynamics, elucidating the electromagnetic damping effects that significantly reduce wheel vibration and improve grinding performance. Experimental results reveal microstructural changes in Inconel 718 under magnetic field influence, including reduced grain size, deformation, and dislocation movement. Furthermore, the study elucidates the effects of magnetic fields on thermodynamics and recrystallization during the grinding process. These findings provide critical insights into the behavior of materials under magnetic field-assisted conditions, offering a promising solution to improve the grindability and surface integrity of difficult-to-machine nickel-based superalloys. The research underscores the potential of MFAUPG to achieve ultra-precision machining and enhance mechanical properties, thereby laying the groundwork for future innovations in economically sustainable grinding practices.

镍基高温合金因科乃尔718因其卓越的机械强度、抗疲劳性、抗腐蚀和抗氧化性在航空航天和汽车工业中至关重要。然而，镍基合金的加工在超精密磨削（UPG）方面面临着巨大的挑战，导致砂轮振动过大，表面质量差。本研究介绍了一种创新的磁场辅助超精密磨削（MFAUPG）技术，代表了磁场辅助磨削工艺应用的进步。建立了将磁场与磨削动力学联系起来的理论模型，阐明了电磁阻尼能显著降低砂轮振动，提高磨削性能。实验结果表明，在磁场作用下，Inconel 718的显微组织发生了变化，包括晶粒尺寸减小、变形和位错移动。此外，研究还阐明了磁场对磨削过程中热力学和再结晶的影响。这些发现为材料在磁场辅助条件下的行为提供了重要的见解，为提高难加工镍基高温合金的可磨削性和表面完整性提供了有希望的解决方案。该研究强调了MFAUPG在实现超精密加工和提高机械性能方面的潜力，从而为未来经济可持续磨削实践的创新奠定了基础。

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引用次数: 0

A novel suppressing evaporation method for enhancing micro-complex magnesium alloy parts additive manufacturing 一种增强微复杂镁合金零件增材制造的抑制蒸发新方法

IF 14 1区工程技术 Q1 ENGINEERING, MANUFACTURING

International Journal of Machine Tools & Manufacture

Pub Date : 2025-05-01 DOI: 10.1016/j.ijmachtools.2025.104281

Lin Su , Xujiang Chao , Jun Luo, Lei Zhao, Yi Zhou, Lewen Yang, Lehua Qi

The increasing demand for micro-complex and customizable magnesium (Mg) alloy structures presents significant challenges for additive manufacturing (AM), particularly in controlling porosity and achieving high-dimensional accuracy. These challenges arise from bubble entrapment and explosive events caused by intense Mg evaporation. This study, for the first time, elucidates the fundamental mechanism underlying these defects, identifying spontaneous bubble nucleation and subsequent explosions within the melt pool as the root cause. In metal droplet-based AM (MDBM), experiments demonstrate that larger bubbles destabilize droplets and disrupt deposition trajectories due to intensified energy release, ultimately degrading print quality. To address this issue, a bubble nucleation and growth model, independent of specific Mg alloy AM methods, was developed. Based on this model, a novel strategy was proposed to mitigate Mg evaporation-induced defects. By identifying a critical bubble nucleation temperature, it was established that operating below this threshold completely suppresses bubble nucleation, thereby preventing associated defects. For conditions exceeding this temperature, the bubble growth model enables precise regulation of bubble size through process parameter optimization, effectively minimizing defects and enhancing structural integrity. As a result, the fabricated structures exhibit high dimensional precision and superior mechanical performance, characterized by pore-free microstructures, minimal dimensional deviation, and enhanced mechanical properties. This study introduces a parameter-driven method for suppressing Mg evaporation-induced defects across various Mg alloy AM technologies, with potential applicability to other highly evaporative metal AM processes. Moreover, it represents the first successful fabrication of micro-complex structures using highly evaporative metals, expanding the material selection for MDBM.

对微复杂和可定制镁合金结构的需求不断增长，给增材制造（AM）带来了重大挑战，特别是在控制孔隙率和实现高尺寸精度方面。这些挑战来自气泡夹持和剧烈的Mg蒸发引起的爆炸事件。这项研究首次阐明了这些缺陷的基本机制，确定了熔池内自发气泡成核和随后的爆炸是根本原因。在基于金属液滴的增材制造（MDBM）中，实验表明，由于能量释放加剧，较大的气泡使液滴不稳定，并破坏沉积轨迹，最终降低打印质量。为了解决这一问题，开发了一个独立于特定镁合金增材制造方法的气泡成核和生长模型。在此基础上，提出了一种减轻Mg蒸发缺陷的新策略。通过确定临界气泡成核温度，确定在此阈值以下操作完全抑制气泡成核，从而防止相关缺陷。对于超过该温度的条件，气泡生长模型可以通过工艺参数优化精确调节气泡尺寸，有效地减少缺陷，提高结构完整性。结果表明，制备的结构具有较高的尺寸精度和优异的力学性能，具有无孔微结构，尺寸偏差最小，力学性能增强的特点。本研究介绍了一种参数驱动的方法，用于抑制各种镁合金增材制造技术中Mg蒸发引起的缺陷，该方法可能适用于其他高蒸发金属增材制造工艺。此外，它代表了首次使用高蒸发性金属成功制造微型复杂结构，扩大了MDBM的材料选择。

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引用次数: 0

Single-sensor-based reconstruction of force and displacement fields for thin-walled cylindrical shells milling 基于单传感器的薄壁圆柱壳铣削力和位移场重建

IF 14 1区工程技术 Q1 ENGINEERING, MANUFACTURING

International Journal of Machine Tools & Manufacture

Pub Date : 2025-05-01 DOI: 10.1016/j.ijmachtools.2025.104282

Jie Chen , Haifeng Ma , Qinghua Song , Yukui Cai , Zhanqiang Liu

The cutting process of thin-walled cylindrical shells involves complex working conditions, and it is difficult to measure the cutting force and vibration displacement at the cutting point in real time. To address this issue, a method is proposed to reconstruct the force and displacement fields of the cylindrical shell in real time using only a single displacement sensor. Based on the first-order shear deformation theory and the artificial spring technique, the wave method can be employed to simultaneously obtain the natural frequencies and analytical mode shape functions of the cylindrical shell with elastic boundary. The dynamic behavior of the cylindrical shell is characterized by the superposition of mode shapes, thereby determining the force-displacement mapping relationship for the entire cylindrical shell. Utilizing in-situ measurement, the time-varying force and displacement fields are reconstructed in real time. Unlike existing methods for reconstructing the displacement field of thin-walled workpieces, one unique feature of this study is the simultaneous real-time reconstruction of the force and the displacement fields using single-point measurement information, providing higher reconstruction accuracy with fewer sensors, thus ensuring practicality and reliability of the results. Through simulation and experimental application to the force and displacement fields reconstruction of cylindrical shell under concentrated and moving force (e.g., cutting process), its practicality as a real-time tool for continuously monitoring cutting force and displacement of cylindrical shell during the cutting process has been demonstrated.

薄壁圆柱壳的切削过程工况复杂，切削力和切削点的振动位移难以实时测量。针对这一问题，提出了一种利用单个位移传感器实时重建圆柱壳的力场和位移场的方法。基于一阶剪切变形理论和人工弹簧技术，采用波动法可以同时获得具有弹性边界的圆柱壳的固有频率和解析模态振型函数。圆柱壳的动力特性表现为模态振型的叠加，从而确定了整个圆柱壳的力-位移映射关系。利用原位测量，实时重建随时间变化的力场和位移场。与现有薄壁工件位移场重建方法不同，本研究的独特之处在于利用单点测量信息同时实时重建力场和位移场，以较少的传感器提供更高的重建精度，从而保证了结果的实用性和可靠性。通过对集中力和移动力（如切削过程）作用下圆柱壳的力场和位移场重建的仿真和实验应用，验证了其作为连续监测圆柱壳切削过程中切削力和位移的实时工具的实用性。

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引用次数: 0

Enhanced strength-ductility synergy in laser directed energy deposited IN718 superalloys through heterogeneous deformation nanostructures 通过异质变形纳米结构提高激光定向能沉积 IN718 超合金的强度-电导率协同效应

IF 14 1区工程技术 Q1 ENGINEERING, MANUFACTURING

International Journal of Machine Tools & Manufacture

Pub Date : 2025-04-16 DOI: 10.1016/j.ijmachtools.2025.104280

Yao Li , Mengyang Li , Hao Yang , Xiaofeng Dang , Luqing Cui , Yang Jiao , Zhiping Sun , Ting Guo , Weifeng He

Laser directed energy deposition (LDED) shows great promise for repairing superalloy components of aeroengines but often results in coarse microstructures, porosity, and tensile residual stresses. Herein, post-process ultrasonic impact treatment (UIT) is adopted to effectively regulate the surface microstructure and residual stresses in LDED-fabricated IN718 superalloys, enhancing the strength-ductility synergy. The UIT process optimization is achieved through a systematic investigation of the effect of output powers on surface roughness, porosity, deformation microstructure, microhardness distribution, residual stress profile, and tensile behavior. Particularly, a finite element model for simulating residual stress field induced by ultrasonic impact is established, showcasing excellent agreement with experimental measurements. UIT-induced substantial dislocation and twinning activities result in depth-dependent heterogeneous deformation nanostructures, including alternating nano-grains and nano-laminated composite structures on the top surface (<8 μm), dense nanotwins (∼30 μm depth), and substantial dislocation tangles and pile-ups (∼150 μm depth). Compared to untreated samples, the yield strength of the samples treated with optimal UIT parameters increased by ∼40%, with negligible ductility loss. The synergistic strengthening mechanisms are mainly attributed to the work hardening and boundary strengthening. To decouple these effects, a quantitative framework that correlates with depth-dependent dislocation populations and grain/nanotwin sizes is proposed, demonstrating good consistency with experimental measurements. The preserved ductility stems from a macroscopic deformation delocalization strategy facilitated by the hetero-deformation induced stress, compressive residual stress, and reduced porosity, together with the near-surface heterogeneous nanostructures enabling deformation accommodation at the micro-scale. This work elucidates the enhanced strength-ductility synergy through surface heterogeneous nanostructures and provides practical guidance for the additive manufacturing of high-performance materials.

激光定向能沉积技术（LDED）在修复航空发动机的高温合金部件方面显示出巨大的前景，但通常会导致粗糙的显微组织、孔隙和拉伸残余应力。本文采用后处理超声冲击处理（UIT）有效调节led制造的IN718高温合金的表面组织和残余应力，增强了强度-塑性协同效应。通过系统地研究输出功率对表面粗糙度、孔隙率、变形微观结构、显微硬度分布、残余应力分布和拉伸行为的影响，实现了UIT工艺优化。建立了超声冲击残余应力场的有限元模拟模型，与实验结果吻合良好。单元诱导的大量位错和孪晶活动导致深度依赖的非均质变形纳米结构，包括顶部表面（<8 μm）的纳米晶粒和纳米层状复合结构的交替，密集的纳米孪晶（~ 30 μm深度），以及大量的位错缠结和堆积（~ 150 μm深度）。与未经处理的样品相比，经过最佳UIT参数处理的样品的屈服强度提高了约40%，而延性损失可以忽略不计。协同强化机制主要是加工硬化和边界强化。为了解耦这些影响，提出了一个与深度相关的位错种群和晶粒/纳米孪晶尺寸相关的定量框架，证明了与实验测量的良好一致性。保留的延性源于宏观变形脱域策略，由异质变形诱导应力、压缩残余应力和降低孔隙率促进，以及在微观尺度上实现变形调节的近表面非均质纳米结构。本研究阐明了通过表面非均质纳米结构增强的强度-延性协同作用，为高性能材料的增材制造提供了实践指导。

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引用次数: 0

On-line laser shielding of hydrogen-induced pores in arc-directed energy deposition 在线激光屏蔽电弧定向能量沉积中的氢致孔隙

IF 14 1区工程技术 Q1 ENGINEERING, MANUFACTURING

International Journal of Machine Tools & Manufacture

Pub Date : 2025-04-12 DOI: 10.1016/j.ijmachtools.2025.104279

Qinghu Guo , Yangyi Pan , Yili Wang , Shiwei Hua , Ling Cen , Ming Gao , Xinyuan Jin , Xianfeng Li , Chen Zhang , Sheng Liu

The detrimental effects of pollutant elements in arc-directed energy deposition (arc-DED), particularly hydrogen-induced porosity in aluminum alloys, pose critical challenges for structural integrity. While pollutant shielding is commonly employed for pore suppression, the risk of hydrogen contamination from repeated remelting of deposited layers remains largely overlooked. This study revealed that even trace surface oxides on deposited layers critically governed hydrogen pore nucleation. Microstructural characterization demonstrated a synergistic clustering mechanism among oxides, hydrogen, and pores, where oxides act as dual-functional sites for hydrogen carriers and trappers. To address this, we developed an innovative on-line laser shielding-enhanced arc-DED system integrating a high-frequency nanosecond pulsed laser with arc plasma. This hybrid approach achieved in situ oxide purification within the molten pool, reducing porosity by 98.1 % compared to conventional arc-DED. The laser-arc synergy demonstrated amplified shielding efficiency, with the arc plasma enhancing laser-induced oxide removal rate by 9.6 times. Crucially, this technology disrupted the oxide-mediated hydrogen transportation pathway while eliminating hydrogen-trapping effects in the molten pool. Implementation in Al-Zn-Mg-Cu alloys significantly improves ductility by minimizing porosity at deformation-sensitive interlayer regions. Process scalability was further verified in Al-Mg alloys, achieving comparable porosity reduction. By decoupling the dual roles of oxides in hydrogen carriers and trappers, this work establishes a paradigm-shifting strategy for pore control in arc-DED, offering a versatile platform for processing hydrogen/oxygen-sensitive metals with enhanced mechanical performance.

在电弧定向能沉积（arc-DED）中，污染物元素的有害影响，特别是铝合金中的氢致孔隙，对结构完整性提出了严峻的挑战。虽然污染物屏蔽通常用于孔隙抑制，但沉积层反复重熔造成氢污染的风险在很大程度上被忽视了。该研究表明，即使是沉积层上的微量表面氧化物也对氢孔成核起着关键的控制作用。微观结构表征表明，氧化物、氢和孔隙之间存在协同聚类机制，其中氧化物作为氢载体和捕集剂的双重功能位点。为了解决这个问题，我们开发了一种创新的在线激光屏蔽增强电弧ded系统，该系统集成了高频纳秒脉冲激光器和电弧等离子体。这种混合方法实现了熔池内的原位氧化物净化，与传统的弧形ded相比，孔隙率降低了98.1%。激光-电弧协同作用增强了屏蔽效率，电弧等离子体使激光诱导的氧化物去除率提高了9.6倍。至关重要的是，该技术破坏了氧化物介导的氢运输途径，同时消除了熔池中的氢捕获效应。在Al-Zn-Mg-Cu合金中，通过最小化变形敏感层间区域的孔隙率，显著提高了延展性。在Al-Mg合金中进一步验证了工艺的可扩展性，实现了类似的孔隙率降低。通过将氧化物在氢载体和捕集剂中的双重作用解耦，该研究为弧形ded的孔隙控制建立了一种范式转换策略，为加工具有增强机械性能的氢/氧敏感金属提供了一个通用平台。

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引用次数: 0

Towards understanding the polishing behavior of thin anisotropic crystals: Coupling, discrepancy, and control across scales 了解各向异性晶体的抛光行为：耦合、差异和跨尺度控制

IF 14 1区工程技术 Q1 ENGINEERING, MANUFACTURING

International Journal of Machine Tools & Manufacture

Pub Date : 2025-04-01 DOI: 10.1016/j.ijmachtools.2025.104269

Wei Gao , Caoyang Xue , Qi Sun , Fang Han , Bing-Feng Ju , Li-tian Xuan , Junjie Zhang , Wule Zhu

Thin anisotropic crystals (TACs) have potential applications in semiconductors, microelectronics, and aerospace. However, polishing a TAC workpiece with a compliant tool is highly challenging because of its susceptibility to deformation and brittle damage owing to its thin structure. Another significant challenge for polishing is the anisotropic discrepancy, which is highly dependent on the crystal planes/directions. To address these challenges and ultimately realize the process control of polishing a TAC workpiece, this study establishes a comprehensive multiscale modeling framework. The proposed framework analytically incorporates the macroscale tool–TAC interaction mechanics, macro/micro coupling material removal mechanism, and macro/micro coupling subsurface damage behavior according to the physical properties of a TAC workpiece. Experiments at different scales are conducted to validate notable discrepancies in the surface and subsurface material responses in the polishing of a TAC workpiece, agreeing well with analytical predictions. Based on the cross-scale study and framework, space- and time-domain control strategies are proposed, demonstrating the capability for effectively eliminating the anisotropic discrepancy from macro- to microscale and enabling deterministic control in the polishing of TACs.

薄各向异性晶体（TACs）在半导体、微电子和航空航天领域具有潜在的应用前景。然而，由于TAC工件结构薄，容易变形和脆性损伤，因此使用柔性工具抛光TAC工件是非常有挑战性的。抛光的另一个重大挑战是各向异性差异，这高度依赖于晶体平面/方向。为了解决这些挑战并最终实现TAC工件抛光过程控制，本研究建立了一个全面的多尺度建模框架。该框架根据TAC工件的物理特性，将宏观尺度的刀具- TAC相互作用力学、宏/微耦合材料去除机制和宏/微耦合亚表面损伤行为进行了分析。在不同的尺度上进行了实验，以验证TAC工件抛光中表面和地下材料响应的显着差异，与分析预测一致。在跨尺度研究和框架的基础上，提出了空间和时域控制策略，证明了该策略能够有效消除宏观到微观尺度的各向异性差异，实现tac抛光过程的确定性控制。

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