Journal of Manufacturing Processes最新文献

Effect of minimum quality lubrication on micromilling of TiBw/TA15 composites considering tool wear 考虑刀具磨损的最低质量润滑对TiBw/TA15复合材料微铣削的影响

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-17 DOI: 10.1016/j.jmapro.2026.01.046

Chaoqun Wu , Yi Chen , Minghui Yang , Yufei Tang , Yun Cheng

The network-structured TiBw/TA15 composites are promising for aerospace but difficult to micromachining. Minimum quantity lubrication (MQL) is attractive for composites machining, yet its effect on surface quality in TiBw/TA15 micromilling remains unclear. The multiphase microstructures of TiBw/TA15 induce brittle-plastic removal and accelerates tool wear. Consequently, the MQL lubrication and tool wear are tightly coupled in evaluating surface quality, the mechanistic elucidation of MQL and machining-parameter effects remain challenging. To address this gap, this study integrates the computational fluid dynamics (CFD) modeling of oil-mist delivery with finite-element analysis (FEA) of multiphase material removal to interpret the results of systematic micromilling experiments across increasing cutting distances. The results show that MQL improves surface quality relative to dry cutting by suppressing the irregular plastic flow of TA15, while TiBw fractures remain but contribute less to surface roughness. The parameter effects are stage-dependent: In initial wear (≤20 mm), radial cutting depth governs the surface roughness through lubrication effectiveness and tool edge geometry, and a moderate value of 60 μm is recommended. In stable wear (>20 mm), spindle speed becomes dominant by altering the lubricant residence and matrix plastic deformation, and the high value of 30,000 rpm is discouraged. A small feed rate (3 μm/tooth) is not recommended due to the intensified ploughing effect and tool wear. MQL ensures consistent surface roughness values remaining under 300 nm, even as tool wear occurs. These findings could provide critical guidance for precision machining of TiBw/TA15 composites.

网状结构TiBw/TA15复合材料在航空航天领域具有广阔的应用前景，但微加工难度较大。最小量润滑（MQL）在复合材料加工中很有吸引力，但其对TiBw/TA15微铣削表面质量的影响尚不清楚。TiBw/TA15的多相组织诱导脆性塑性去除，加速刀具磨损。因此，MQL润滑和刀具磨损在表面质量评价中是紧密耦合的，对MQL和加工参数影响的机理解释仍然具有挑战性。为了解决这一差距，本研究将油雾输送的计算流体动力学（CFD）建模与多相材料去除的有限元分析（FEA）相结合，以解释系统微铣削实验在增加切削距离时的结果。结果表明，相对于干切削，MQL通过抑制TA15的不规则塑性流动改善了表面质量，而TiBw断口仍然存在，但对表面粗糙度的影响较小。参数的影响是阶段相关的：在初始磨损（≤20 mm）时，径向切削深度通过润滑效果和刀具边缘几何形状来控制表面粗糙度，建议采用60 μm的适中值。在稳定磨损（> 20mm）时，通过改变润滑油停留和基体塑性变形，主轴转速成为主导，不鼓励30,000 rpm的高值。由于犁耕效应加剧，刀具磨损严重，不建议采用小进给速度（3 μm/齿）。MQL确保表面粗糙度值保持在300nm以下，即使发生刀具磨损。研究结果可为TiBw/TA15复合材料的精密加工提供重要指导。

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引用次数: 0

Achieving high mechanical properties and outstanding thermally conductive Al/AlN direct-bonded joints through interfacial oxide barrier elimination 通过消除界面氧化障碍，获得高机械性能和优异的导热性Al/AlN直接键合接头

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-17 DOI: 10.1016/j.jmapro.2026.01.032

Rui Xu , Xinfei Zhang , Ce Wang , XinYue Li , Hangze Zhou , Shuye Zhang , Tong Wu , Fugang Lu , Peng He , Tiesong Lin , Panpan Lin , Xiaoming Duan

A novel low-temperature bonding approach via the Al-Si-Mg inactive interlayer was proposed to fabricate Al/AlN joints for the first time, achieving a shear strength of 105.2 MPa and a thermal conductivity as high as 216.1 W/(m·K). The joints comprised nanoscale Mg-Al-O compounds, α-Al, and Si phases. By the deoxidation reaction of Mg atoms in the interlayer with AlN_xO_y of the AlN surface, Mg₃Al₁₄O₂₄ was formed and the AlN with a relatively high adsorption energy was exposed. Thus, the AlN was bonding with Al to achieve a seamless and robust Al/AlN direct-bond interface. The influence of temperature on the mechanical properties and heat transfer characteristics of joints was systematically examined. By increasing the temperature to eliminate the primary Si, the joint strength peaked at 105.2 MPa, surpassing that of the metal/AlN joints brazed at higher temperatures by active brazing. Through adjusting the temperature to inhibit the diffusion of Si atoms, the lattice distortion of Al was decreased, and the best thermal conductivity reached 216.1 W/(m·K), far exceeding that of Cu/AlN joints using active brazing or other methods. This bonding approach provides a novel strategy for the high-performance manufacturing of AlN substrates.

首次提出了一种利用Al- si - mg非活性中间层制备Al/AlN接头的新型低温结合方法，其抗剪强度达到105.2 MPa，导热系数高达216.1 W/（m·K）。接头由纳米级Mg-Al-O化合物、α-Al和Si相组成。中间层中的Mg原子与AlN表面的AlNxOy发生脱氧反应，生成Mg3Al14O24，暴露出具有较高吸附能的AlN。因此，AlN与Al键合，实现了无缝且坚固的Al/AlN直接键合界面。系统地研究了温度对接头力学性能和传热特性的影响。通过提高钎焊温度消除初生Si，接头强度达到105.2 MPa，超过了活性钎焊在较高温度下钎焊的金属/AlN接头。通过调节温度抑制Si原子的扩散，降低了Al的晶格畸变，最佳导热系数达到216.1 W/(m·K)，远远超过了采用活性钎焊或其他方法的Cu/AlN接头。这种键合方法为AlN基板的高性能制造提供了一种新的策略。

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引用次数: 0

Machine learning in tribology: A review on framework, case studies, and future perspectives 摩擦学中的机器学习：框架、案例研究和未来展望综述

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-17 DOI: 10.1016/j.jmapro.2026.01.029

Yadong Li , Bing Liu , Zhenghua Chang , Zhaofu Zhang , Wengen Ouyang , Zishang Liu , Quanyu Jiang , Yizhe Liu , Anyi Huang , Yuxin Wu , Zheng Hu , Hai Lan , Ming Han , Yunjian Bai , Kun Zhang , Bingchen Wei

Tribological materials play a critical role in high-end fields such as aerospace, rail transportation, manufacturing processes and energy equipment. However, their friction and wear behaviors are highly complex, governed by the coupled effects of multi-scale and multi-physics interactions. Traditional research approaches, which rely heavily on experiments and empirical knowledge, are costly, time-consuming, and often insufficient to uncover the underlying mechanisms. With the rapid development of artificial intelligence (AI), machine learning (ML) has emerged as a powerful tool in tribology research, leading to the introduction of the concept of tribo-informatics. This review systematically summarizes the methodological framework of ML in tribology, covering data acquisition, feature selection, model selection and optimization, performance evaluation and validation, as well as result interpretation. Key methodological advances, including data augmentation, physics-informed approaches, and interpretability techniques, are emphasized and systematically discussed. Representative applications demonstrate that data-driven interpretable learning, multi-source data fusion, and physics-informed ML (PIML) models can enhance prediction accuracy and robustness while revealing fundamental tribological mechanisms. Moreover, ML has been widely applied to the design and performance optimization of novel tribological materials, accelerating the materials development cycle. Finally, the future prospects of tribo-informatics are outlined, highlighting high-quality database construction, physics-driven integration, interpretability enhancement, and small-sample learning as key research trends. This review aims to provide a systematic methodological reference for tribology research and to promote the paradigm shift from experience-driven to data–mechanism integrated approaches.

摩擦学材料在航空航天、轨道交通、制造工艺和能源设备等高端领域发挥着关键作用。然而，它们的摩擦磨损行为是高度复杂的，受多尺度和多物理场相互作用的耦合影响。传统的研究方法严重依赖实验和经验知识，成本高、耗时长，而且往往不足以揭示潜在的机制。随着人工智能（AI）的快速发展，机器学习（ML）已成为摩擦学研究的有力工具，从而引入了摩擦学信息学的概念。本文系统总结了机器学习在摩擦学中的方法论框架，包括数据采集、特征选择、模型选择与优化、性能评估与验证以及结果解释。关键方法的进步，包括数据增强，物理知情的方法，和可解释性技术，强调和系统地讨论。代表性的应用表明，数据驱动的可解释学习、多源数据融合和物理信息ML （PIML）模型可以提高预测精度和鲁棒性，同时揭示基本的摩擦学机制。此外，机器学习已被广泛应用于新型摩擦学材料的设计和性能优化，加快了材料的开发周期。最后，对摩擦信息学的未来前景进行了展望，强调了高质量数据库建设、物理驱动集成、可解释性增强和小样本学习是关键的研究趋势。本文旨在为摩擦学研究提供系统的方法论参考，促进摩擦学研究范式从经验驱动转向数据机制集成。

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引用次数: 0

A robotic grinding parameter optimization approach considering tool wear to guarantee material removal accuracy and surface quality 考虑刀具磨损的机器人磨削参数优化方法以保证材料去除精度和表面质量

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-16 DOI: 10.1016/j.jmapro.2026.01.001

Haiqing Chen, Jixiang Yang, Qi Qi, Han Ding

High-precision curved parts grinding must meet strict material removal control and surface quality constraint at the same time. In actual grinding process, the tool wear will cause its material removal ability to gradually decay and simultaneously induce changes in workpiece surface roughness, while existing studies have not considered the dynamic impact of tool wear to simultaneously guarantee material removal accuracy and surface quality. This paper proposes a robotic grinding parameter optimization method considering tool wear to guarantee material removal accuracy while maintain surface quality. Firstly, after quantifying the tool wear over usage time, the material removal depth coefficient under different process parameters at different times is predicted by multivariate Gaussian process regression, and a material removal model considering tool wear is developed. Secondly, a surface roughness prediction model is constructed in combination with the tool wear degree to characterize the influence of tool wear on surface quality. On this basis, a robotic grinding process parameter optimization algorithm considering tool wear is developed, which achieves accurate compensation of material removal accuracy by adjusting process parameters, while ensuring that the surface quality meets the requirements. Finally, experimental verification results show that compared with the robotic grinding process parameter optimization method without considering tool wear and surface roughness constraint, the proposed method significantly improves the material removal accuracy and surface quality of the curved parts after grinding.

高精度曲面零件磨削必须同时满足严格的材料去除控制和表面质量约束。在实际磨削过程中，刀具磨损会导致其材料去除能力逐渐衰减，同时引起工件表面粗糙度的变化，而现有研究并未考虑刀具磨损的动态影响，以同时保证材料去除精度和表面质量。提出了一种考虑刀具磨损的机器人磨削参数优化方法，在保证材料去除精度的同时保持表面质量。首先，在量化刀具磨损随使用时间的变化后，利用多元高斯过程回归预测不同工艺参数下不同时间的材料去除深度系数，建立了考虑刀具磨损的材料去除模型；其次，结合刀具磨损程度建立表面粗糙度预测模型，表征刀具磨损对表面质量的影响；在此基础上，开发了一种考虑刀具磨损的机器人磨削工艺参数优化算法，在保证表面质量满足要求的前提下，通过调整工艺参数实现对材料去除精度的精确补偿。实验验证结果表明，与不考虑刀具磨损和表面粗糙度约束的机器人磨削工艺参数优化方法相比，该方法显著提高了曲面零件磨削后的材料去除精度和表面质量。

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引用次数: 0

Fusion instability prediction and mechanism exploration in robotic narrow-gap GMAW via frequency-attention enhanced ConvNeXt 基于频率关注增强卷积next的机器人窄间隙GMAW融合不稳定性预测及机制探讨

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-16 DOI: 10.1016/j.jmapro.2026.01.028

Ruiyan Jia , Haichao Li , Fangkai Wei , Jing Li , Yixuan Ma , Fei Liu , Lianheng Guo

Robotic narrow-gap gas metal arc welding (NG-GMAW) is being increasingly adopted in industrial manufacturing. A key challenge is the resulting demand for real-time monitoring of welding fusion quality in intelligent systems. This study proposes a Frequency-Attention Enhanced ConvNeXt (FAE-ConvNeXt) model for predicting fusion instability in robotic NG-GMAW. The proposed model enhances prediction accuracy and industrial applicability through the integration of multidimensional information and targeted handling of temperature characteristics. First, a Multi-Scale Frequency Enhancement Module (MSFEM) is developed. Based on infrared thermal images, MSFEM analyzes the frequency domain features of the molten pool. This algorithm is designed to extract subtle defect features that are often imperceptible in the spatial domain. Subsequently, a Thermal Gradient Adaptive Attention Module (TGAAM) is introduced to capture abrupt temperature transitions. The temperature gradient is incorporated as a physical prior into the attention computation. Through dynamic adjustment of attention regions and the fusion of thermal gradient features, TGAAM achieves a comprehensive analysis of the molten pool. Finally, the integration of these modules into ConvNeXt blocks allows for a coherent fusion of multi-domain features, including spatial, frequency, and thermal gradient information. Experimental results demonstrate that the proposed FAE-ConvNeXt model achieves a prediction accuracy of 98.51%. Visualization analysis reveals that the model concentrates on molten pool regions characterized by sharp changes in temperature gradients when predicting the fusion states. Compared with traditional algorithms, this model overcomes the limitations of single-dimensional feature extraction. By fully leveraging the rich information in molten pool infrared images, this approach provides a robust solution for enhancing the intelligence and stability of robotic NG-GMAW.

机器人窄间隙气体保护金属电弧焊（NG-GMAW）在工业制造中得到越来越多的应用。一个关键的挑战是由此产生的对智能系统中焊接融合质量实时监测的需求。本研究提出了一种频率-注意力增强的ConvNeXt （FAE-ConvNeXt）模型，用于预测机器人NG-GMAW的融合不稳定性。该模型通过融合多维信息和对温度特征的针对性处理，提高了预测精度和行业适用性。首先，研制了多尺度频率增强模块（MSFEM）。基于红外热图像，MSFEM分析了熔池的频域特征。该算法旨在提取在空间域中通常难以察觉的细微缺陷特征。随后，引入了热梯度自适应注意模块（TGAAM）来捕捉温度突变。温度梯度作为物理先验被纳入到注意力计算中。通过对关注区域的动态调整和热梯度特征的融合，TGAAM实现了对熔池的综合分析。最后，将这些模块集成到ConvNeXt块中，可以实现多域特征的相干融合，包括空间、频率和热梯度信息。实验结果表明，所提出的FAE-ConvNeXt模型的预测准确率达到了98.51%。可视化分析表明，该模型在预测熔池状态时，主要集中在温度梯度变化较大的熔池区域。与传统算法相比，该模型克服了一维特征提取的局限性。该方法充分利用熔池红外图像的丰富信息，为提高NG-GMAW机器人的智能和稳定性提供了一种鲁棒的解决方案。

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引用次数: 0

Thermal effects on the material removal mechanism in laser-assisted milling of CFRP 激光铣削CFRP中热效应对材料去除机理的影响

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-15 DOI: 10.1016/j.jmapro.2026.01.033

Chao Zhang , Yinghui Ren , Maojun Li , Chengyang Yu , Minghui Liao , Xiaolin Yu , Qiding Yang

The anisotropy of carbon fiber reinforced plastic (CFRP) leads to an inhomogeneous heat-affected zone (HAZ, the laser-irradiated region with thermal-induced structural and property degradation), which significantly impacts the stability and quality of laser-assisted robotic milling (L-ARM). Based on the heat conduction model and robotic milling platform, this study developed novel finite element models of different zones of HAZ, including matrix recession zone (MRZ, with severe matrix decomposition) and transition zone (TZ, with partial matrix degradation), to reveal the material removal mechanism under different thermal effects. The results show that the energy per unit length (E_l) and temperature distribution significantly impact the morphology and extent of HAZ. Matrix degradation and fiber rebound in the MRZ lead to burr formation. Fiber shearing in the TZ under minor thermal effects produces superior surface quality. Conversely, major thermal effect results in fiber bending and matrix cracks. Notably, cutting force fluctuations are higher in the TZ than in the MRZ, reaching a maximum of 31.74 N during milling of TZ under minor thermal effects (E_l = 150 J/mm), which significantly affects the stability and quality of robotic milling.

碳纤维增强塑料（CFRP）的各向异性导致其热影响区（HAZ）不均匀，这对激光辅助机器人铣削（L-ARM）的稳定性和质量产生了重大影响。基于热传导模型和机器人铣削平台，建立了热影响区不同区域的有限元模型，包括基体退化区（MRZ，基体严重分解）和过渡区（TZ，基体部分降解），揭示了不同热效应下材料的去除机理。结果表明，单位长度能量（El）和温度分布对热影响区形态和程度有显著影响。MRZ中的基体降解和纤维回弹导致毛刺的形成。在热效应较小的情况下，纤维在TZ中剪切产生优异的表面质量。相反，主要的热效应导致纤维弯曲和基体裂纹。值得注意的是，在热效应较小（El = 150 J/mm）的情况下，铣削TZ时的切削力波动幅度比MRZ大，最大可达31.74 N，显著影响机器人铣削的稳定性和质量。

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引用次数: 0

Oxidation and photothermal energy conversion at the laser-induced vapor–liquid interface during laser spot welding 激光点焊过程中气液界面氧化与光热能量转换

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-15 DOI: 10.1016/j.jmapro.2026.01.031

Tao Liu , Shun Xie , Jianglin Zou , Jing Wang , Kaikai Shi , Yuxuan Zhang , Qiang Wu

Studying the oxidation behavior on the molten pool surface during laser spot welding in an atmospheric environment is important for developing molten pool protection strategies and for understanding the laser-induced optical-to-thermal energy conversion at the vapor–liquid interface. This study shows that, under a fixed laser exposure duration, as the laser power increases, the solid-phase heating stage is markedly shortened, the melting stage first lengthens and then shortens, and the vaporization stage continues to extend. Meanwhile, the total laser absorptivity of the metal exhibits a non-monotonic trend, decreasing first and then increasing, and the absorptivity in air is consistently higher than that in argon. Under atmospheric conditions, surface oxidation of the molten pool occurs predominantly during the melting stage, where oxidation of the liquid surface can significantly enhance absorptivity. At low laser power without a vaporization stage, the prolonged melting stage leads to a peak absorptivity of the liquid surface in air that is approximately 14.7% higher than that in argon. At high laser power, laser-induced evaporation suppresses further surface oxidation, causing the absorptivity of the vapor–liquid interface to decrease with increasing power. In addition, the shortening of the melting stage with increasing high laser power is a primary reason why both the extent of surface oxidation and the corresponding absorptivity increment become negligible under atmospheric conditions. Overall, this work elucidates the stage-dependent roles of vapor–liquid interfacial oxidation during laser spot welding and provides a theoretical basis for improving energy coupling efficiency and for designing optimal molten pool protection strategies in high-precision laser melting manufacturing applications.

研究大气环境下激光点焊过程中熔池表面的氧化行为，对于制定熔池保护策略和理解激光诱导的气液界面光热转换具有重要意义。研究表明，在一定的激光照射时间下，随着激光功率的增大，固相加热阶段明显缩短，熔化阶段先变长后变短，汽化阶段持续延长。同时，金属的激光总吸收率呈先减小后增大的非单调趋势，在空气中的吸收率始终高于氩气中的吸收率。在大气条件下，熔池表面氧化主要发生在熔化阶段，此时液面氧化可显著提高吸收率。在没有汽化阶段的低激光功率下，熔化阶段延长导致液体表面在空气中的峰值吸收率比在氩气中的峰值高约14.7%。在高激光功率下，激光诱导的蒸发抑制了进一步的表面氧化，导致气液界面的吸收率随着功率的增加而降低。此外，随着激光功率的增加，熔化阶段的缩短是大气条件下表面氧化程度和相应的吸收率增量可以忽略不计的主要原因。总的来说，本研究阐明了激光点焊过程中气液界面氧化的阶段依赖作用，为高精度激光熔化制造应用中提高能量耦合效率和设计最佳熔池保护策略提供了理论基础。

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引用次数: 0

Plasticity improvement by pulsed electric current during sheet metal forming of Al-Mg alloy strips in different states of hardening 脉冲电流对不同硬化状态下铝镁合金带材成形塑性的改善

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-15 DOI: 10.1016/j.jmapro.2026.01.020

Daniel Dobras , Zbigniew Zimniak , Mateusz Dziubek

Aluminum alloys have high specific strength, which means that their use can result in a reduction in vehicle weight and thus their emissions. However, their formability at room temperature is low. A significant increase in the formability of strain-hardened aluminum alloys can be achieved by applying current pulses during their deformation. However, until now, it has not been possible to achieve this in sheet metal forming of aluminum alloys. This work shows that it is possible to increase the drawability of aluminum alloy sheets in the electrically-assisted deep drawing process. Eliminating the blank holder force during the process, using stainless steel dies and modular punch design enabled the heat transfer to be reduced and the appropriate temperature of the drawpiece to be obtained. Thanks to this, dynamic recovery was triggered while maintaining the mechanical properties of the material. The obtained results will allow the development of the electrically-assisted sheet metal forming, especially the deep drawing processes. The drawability of the material can be increased in these processes by using the economical method of applying current pulses.

铝合金具有很高的比强度，这意味着它们的使用可以减少车辆重量，从而减少排放。然而，它们在室温下的成形性较低。通过在变形过程中施加电流脉冲，可以显著提高应变硬化铝合金的成形性。然而，到目前为止，还不可能在铝合金的金属板成形中实现这一目标。这项工作表明，在电动辅助拉深工艺中，提高铝合金板的拉伸性是可能的。采用不锈钢模具和模块化冲床设计，消除了压边力，减少了热传递，获得了合适的拉拔件温度。因此，在保持材料机械性能的同时触发了动态恢复。所得结果将为电辅助板料成形，特别是深拉深成形的发展提供理论依据。在这些过程中，通过使用经济的方法施加电流脉冲，可以增加材料的拉伸性。

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引用次数: 0

Enhanced formability of age-hardened 2219 aluminum alloy: role of through-thickness stress and temperature synergy 时效硬化2219铝合金成形性能的提高：厚度应力和温度协同作用

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-15 DOI: 10.1016/j.jmapro.2026.01.018

Ye Tian , Wen Zhang , Xincun Zhuang , Zhen Zhao

The limited formability of age-hardened aluminum alloys at room temperature presents significant manufacturing challenges for fabricating complex components. This study systematically investigates the synergistic enhancement mechanism of through-thickness stress and forming temperature on the formability of age-hardened 2219 aluminum alloy. A flat-bottom stretching test platform integrated with through-thickness stress control and temperature regulation was developed to evaluate the limiting forming height (LFH) under varying thermo-mechanical conditions (75–225 °C, 0–180 MPa). Contrary to the commonly assumed monotonic relationship, the results reveal a critical threshold of through-thickness stress (Pc) for significant formability improvement. And the P_C decreases as the forming temperature increases. Below Pc, LFH exhibited negligible improvement. When stress exceeded Pc, LFH increased sharply. As the stress continues to increase, the enhancement effect on LFH gradually diminishes. Microstructural analysis indicated that through-thickness stress effectively reduces damage accumulation by inhibiting the fragmentation of precipitates and the growth of voids. The theoretical predictions for P_C closely align with experimental results under conditions where stress triaxiality shifts from positive to negative values. In hole-flanging applications, a through-thickness stress of 120 MPa increased flange height by 17.4% and reduces required forming temperatures by 25 °C. These findings provide not only a fundamental insight into the non-linear effect of through-thickness stress but also practical strategies for efficient forming of age-hardened aluminum alloys.

时效硬化铝合金在室温下有限的成形性给复杂部件的制造带来了巨大的挑战。本研究系统地探讨了透厚应力和成形温度对时效硬化2219铝合金成形性能的协同增强机制。开发了一个集全厚应力控制和温度调节于一体的平板拉伸测试平台，以评估不同热机械条件（75 ~ 225℃，0 ~ 180 MPa）下的极限成形高度（LFH）。与通常假设的单调关系相反，结果揭示了显著改善成形性的贯穿厚度应力（Pc）的临界阈值。PC随成形温度的升高而降低。低于Pc， LFH的改善可以忽略不计。当应力超过Pc时，LFH急剧增加。随着应力的继续增大，对LFH的增强作用逐渐减弱。显微组织分析表明，透厚应力通过抑制析出相的破碎和孔洞的生长，有效地减少了损伤的积累。当应力三轴性由正向负转变时，理论预测与实验结果吻合较好。在孔翻边应用中，120 MPa的全厚应力可使法兰高度提高17.4%，并将所需的成形温度降低25℃。这些发现不仅对贯穿厚度应力的非线性效应提供了基本见解，而且为时效硬化铝合金的有效成形提供了实用策略。

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引用次数: 0

Strengthening mechanism of IN 718 alloy fabricated by ultrasonic vibration-assisted laser directed energy deposition with heat treatment 超声振动辅助激光定向能沉积热处理in718合金的强化机理

IF 6.8 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes

Pub Date : 2026-01-14 DOI: 10.1016/j.jmapro.2026.01.003

Xiaoxia Qi , Yanle Li , Jiyu Du , Weiguang Fan , Yunjian Bai , Heng Chen , Fangyi Li

Continuous chain-like Laves phase is a significant factor leading to the failure of additively manufactured IN 718 alloy, resulting in the restricted application in critical aerospace components. To obtain high performance for IN 718 alloy, a novel processing strategy of laser directed energy deposition (LDED) combining bi-dimensional ultrasonic vibration (UV) and double aging (DA) is proposed to regulate Laves phase and γ″ phase. The DA-treated IN 718 sample with UV (UV-718A) achieves an ultimate tensile strength of 1389.7 ± 22.5 MPa and an elongation of 14.0 % ± 0.5 %, which are increased by 9.13 % and 33.3 %, respectively, compared to the DA-treated IN 718 without UV (NU-718A). Notably, the contributions of UV to yield strength before and after DA were 70.2 MPa and 113.7 MPa, respectively. The outstanding performance of the UV-718A sample was mainly attributed to refined grains and granular Laves phase surrounded by uniformly distributed γ′/γ″ phases. The finer grains and granular Laves phases result from the homogenization of alloy composition under UV, which promotes more uniform precipitation of γ″ phase (the distribution width expands by 80.4 %) during subsequent DA. Under the UV effect, the chain-like Laves phase is transformed into granular structures, and its content is reduced by 30.8 %, which contributes to improved ductility. Furthermore, fractographic analysis reveals that the failure mechanism for both the NU-718A and UV-718A samples is microvoids aggregation-induced fracture, where microvoids are caused by self-fragmentation of chain-like Laves phases and debonding of granular Laves phases. This research provides a processing strategy for high-performance critical aerospace components.

连续链状Laves相是导致增材制造的in718合金失效的重要因素，限制了其在航空航天关键部件上的应用。为了获得高性能的IN 718合金，提出了一种结合二维超声振动（UV）和双时效（DA）的激光定向能沉积（ld）工艺策略来调节Laves相和γ″相。经UV （UV- 718a）处理的IN 718试样的抗拉强度为1389.7±22.5 MPa，伸长率为14.0%±0.5%，分别比未经UV （NU-718A）处理的IN 718试样提高了9.13%和33.3%。值得注意的是，UV对DA前后屈服强度的贡献分别为70.2 MPa和113.7 MPa。UV-718A样品的优异性能主要归功于由均匀分布的γ′/γ″相包围的细化晶粒和粒状Laves相。在UV作用下，合金成分均质化，使得γ″相的析出更加均匀（分布宽度扩大了80.4%）。在UV作用下，条状Laves相转变为粒状组织，其含量降低了30.8%，有利于提高塑性。断口形貌分析表明，NU-718A和UV-718A试样的破坏机制均为微孔洞聚集断裂，微孔洞是由链状Laves相的自破碎和粒状Laves相的脱粘引起的。该研究为高性能航空航天关键部件的加工提供了一种策略。

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