Journal of Materials Processing Technology最新文献

{"title":"Interlayer time as a robust, geometry-agnostic predictor of microstructural and mechanical properties evolution in PBF-LB/M Ti6Al4V alloy","authors":"A.E. Medvedev ,&nbsp;S. Brudler ,&nbsp;S. Piegert ,&nbsp;T. Illston ,&nbsp;M. Qian ,&nbsp;M. Brandt","doi":"10.1016/j.jmatprotec.2025.118858","DOIUrl":"10.1016/j.jmatprotec.2025.118858","url":null,"abstract":"<div><div>Process optimisation during laser-based powder bed fusion of metals (PBF-LB/M) has in the past been shown to offer a large amount of control over microstructure and mechanical properties of materials, especially in the ability to utilise the <em>in-situ</em> thermal treatments, facilitated by heat accumulation during the fabrication process. Interlayer time (<span><math><mi>ILT</mi></math></span>) in PBF-LB/M of Ti6Al4V titanium alloy was previously shown to play a significant role in controlling the final microstructure, however, was also prone to occasional impurity pick-up facilitated by an increase in part temperature during the fabrication. However, a systematic understanding of the interplay between <span><math><mi>ILT</mi></math></span>, process parameters, build size, heat accumulation and impurity pick-up was lacking. Here, we evaluated the effect of <span><math><mi>ILT</mi></math></span> in a wide range (10 – 73 s) as well as part geometry on the evolution in microstructure, mechanical properties and residual stresses generated in PBF-LB/M Ti6Al4V. This study confirms that <span><math><mrow><mi>IL</mi><mi>T</mi></mrow></math></span> &lt; 40 s is linked to dramatic heat accumulation, significant microstructure coarsening as well as reduction in strength and residual stresses, while further reduction to as low as <span><math><mrow><mi>IL</mi><mi>T</mi></mrow></math></span> ≈ 10 s led to sample glow, surface discoloration and impurity pick-up with consequent increase in hardness and embrittlement, manifesting a crucial limitation on the <em>in-situ</em> heat treatment implementation through <span><math><mi>ILT</mi></math></span> control. We further demonstrate that this limitation can be overcome by reducing the cumulative track length per unit volume (via using thicker powder layers and/or wider hatch spacing), which, despite achieving higher overall average temperatures, acquired less impurities due to fewer melting/exposure cycles during fabrication of identical size parts. Further, by virtue of minimising the number of expansion/contraction cycles per part, this approach was shown to be highly effective in reducing the magnitude of residual stress generated in parts. Most importantly, this work demonstrated that the effect of <span><math><mi>ILT</mi></math></span> on the microstructure and mechanical properties of PBF-LB/M Ti6Al4V is largely agnostic to the global part geometry and/or a number of parts in a build, even for vastly different process parameter combinations. This indicates a significant potential for the future development of a new <span><math><mi>ILT</mi></math></span>-derived process optimisation metric for direct and informed design of microstructure and properties in PBF-LB/M Ti6Al4V.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118858"},"PeriodicalIF":6.7,"publicationDate":"2025-04-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143824076","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Stabilization mechanism of arc behavior and droplet transition in laser-arc hybrid welding of NS70 magnesium alloy","authors":"Yunhao Liu ,&nbsp;Xiaojie Cui ,&nbsp;Yanqiu Zhao ,&nbsp;Xiong Zhang ,&nbsp;Peng Li ,&nbsp;Peiyun Xia ,&nbsp;Xiaohong Zhan","doi":"10.1016/j.jmatprotec.2025.118856","DOIUrl":"10.1016/j.jmatprotec.2025.118856","url":null,"abstract":"<div><div>The welding stability for magnesium alloy presents a significant challenge owing to the inherent softness of the welding wire and the propensity for high vaporization rates. The arc behavior and droplet transition, serving as pivotal indicators of welding stability, are mainly concerned. This study conducted laser-arc hybrid welding experiments on NS70 magnesium alloy, a novel lightweight material. The welding process was monitored using multi-source information from infrared temperature measurement, spectroscopy, and high-speed camera imaging. A comparison was made between the droplet transition behaviors during laser- metal inert gas (MIG) and laser-cold metal transfer (CMT) welding processes. The variations in arc plasma morphology, molten pool temperature, and ionization intensity were synchronously detected and quantitatively analyzed. The study investigated the effects of welding current and laser power on arc characteristics and droplet transition behavior in the CMT arc mode. Optimal process parameters were determined based on the weld seam surface quality and porosity rate. The results indicate that the increase of welding current enlarges the arc area, but disturbs plasma morphology. At a current of <em>I</em>= 65 A, the droplet transition frequency increased by 60.4 % compared to that under <em>I</em>= 35 A, and the fish scale density increased by 99.2 %. Analysis of the droplet transfer behavior during the wire feeding and withdrawal phases reveals that a welding current of 35 A and a laser power of 1900 W mitigate the intense droplet impact on the molten pool and the issue of incomplete droplet transfer. These findings provide a reliable basis for industrial welding production of NS70 magnesium alloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118856"},"PeriodicalIF":6.7,"publicationDate":"2025-04-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143828507","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study of viscous layer in friction welding of Fe/Al dissimilar metals: Formation, evolution and effect on joint properties","authors":"Shuai Gong ,&nbsp;Shuhai Chen ,&nbsp;Gaoyang Yu ,&nbsp;Guocheng Shao ,&nbsp;Jihua Huang ,&nbsp;Jian Yang ,&nbsp;Pishi Chen","doi":"10.1016/j.jmatprotec.2025.118850","DOIUrl":"10.1016/j.jmatprotec.2025.118850","url":null,"abstract":"<div><div>In friction welding of aluminum alloys to steel, an interlayer consisting of thermoplastic metal is formed at the interface. However, the current research on this interlayer is still insufficient. In this paper, two different welding control methods are designed using self-developed welding equipment, the control method of “Rotating and Separating after welding” and the control method of “Stopping immediately after welding”. Rotary friction welding of aluminum alloys to steel has been investigated by combining the two control methods. The results show that in rotary friction welding of aluminum alloys to steel, an interlayer consisting of thermoplastic aluminum is formed at the interface, which is called the viscous layer. The formation and evolution of the viscous layer are summarized and quantified by comparing the interface morphology obtained at different times and by different control methods. It was found that the viscous layer first formed at the 1/2–2/3 position of the friction interface, then spread across the interface and finally covered the entire friction interface. At the same time, the interface friction state was changed due to the formation of the viscous layer. The interface friction gradually changed from Coulomb friction between aluminum alloy and steel to adhesive friction between aluminum alloy and viscous layer. It was also found that the viscous layer had an important contribution to the formation of welded joints. The coverage area of the viscous layer, the metallurgical reaction between the viscous layer and the steel, and the microstructure of the viscous layer are the main factors affecting the strength of the joint.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118850"},"PeriodicalIF":6.7,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143824077","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Numerical Simulation and Optimization of Droplet Transition in Bypass-Coupled Twin-Wire Indirect Arc Welding: Insights into Parameter Effects and Process Stability","authors":"Yuhang Zhang ,&nbsp;Dongting Wu ,&nbsp;Zhenhuan Gao ,&nbsp;Haidong Yin ,&nbsp;Liping Nie ,&nbsp;Xiufang Gong ,&nbsp;Ying Liu ,&nbsp;Yong Zou","doi":"10.1016/j.jmatprotec.2025.118853","DOIUrl":"10.1016/j.jmatprotec.2025.118853","url":null,"abstract":"<div><div>This study develops a numerical model for droplet transition in Bypass-Coupled Twin-Wire Indirect Arc Welding (BC-TWIAW), integrating electromagnetic and hydrodynamic interactions. Experimental validation confirms the model’s reliability with less than 10% error. Analysis reveals that shielding gas flow rate, welding current, and wire feed speed jointly govern droplet transition: gas flow rate exceeding 21<!--> <!-->L/min or excessive wire feed speed destabilises the transition, while balanced parameters suppress splashing. The bypass current critically controls the positive droplet stability, evidenced by smaller offset distances at currents between 90-110<!--> <!-->A. The main current, optimal in the range of 110-130<!--> <!-->A, along with the wire feed speed, regulates droplet size and transition frequency. An unbalanced mix between wire feed speeds—positive speeds between 0.1025 and 0.1225<!--> <!-->m/s and negative speeds between 0.14 and 0.16<!--> <!-->m/s—optimises droplet growth and detachment. The identified optimal ranges achieve stability by balancing electromagnetic forces and droplet dynamics, providing a transferable framework for multi-wire welding processes. This work advances process control strategies through systematic parameter space exploration, providing new insights into the optimisation of other welding processes and the control of droplet transition.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118853"},"PeriodicalIF":6.7,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815409","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Constructing heterostructure Ti6Al4V alloy by electropulsing assisted ultrasonic surface strengthening to improve its fretting wear performance","authors":"P.F. Sun ,&nbsp;C.X. Qu ,&nbsp;F.L. Li ,&nbsp;X.Q. Li ,&nbsp;C. Yang ,&nbsp;S.G. Qu","doi":"10.1016/j.jmatprotec.2025.118852","DOIUrl":"10.1016/j.jmatprotec.2025.118852","url":null,"abstract":"<div><div>Simultaneously improving the fatigue performance and wear resistance of titanium alloys is a trade-off process, and the surface mechanical strengthening method is a feasible way to balance the two. The ultrasonic surface strengthening (USS) technology can achieve most of the beneficial effects of other surface mechanical strengthening methods while reducing roughness, but it has the potential to be further enhanced. Besides, the load-dependent fretting wear mechanisms of heterostructure Ti6Al4V alloy prepared by the USS technology have not been systematically analyzed. This study utilized electropulsing assisted ultrasonic surface strengthening (EUSS) technology to enhance the surface properties of heterostructure Ti6Al4V alloy. Through microstructural characterization and theoretical analysis, the surface hardening mechanism of heterostructure Ti6Al4V alloy is elucidated. The results show that the gain effect of the EUSS treatment originates from the electroplasticity, while the opening of the {10−11}&lt; -1–123 &gt; pyramidal slip is considered to be the main cause. Subsequently, fretting wear tests under different loads were designed, combined with Hertzian contact analysis, to elucidate the load-dependent fretting damage mechanisms of heterostructure Ti6Al4V alloy. Heterostructure Ti6Al4V alloy has good fretting wear resistance due to high hardness at low loads, but fretting wear resistance disappears at high loads due to loss of plasticity.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118852"},"PeriodicalIF":6.7,"publicationDate":"2025-04-08","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143824078","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Study on the inhibition mechanism and removal mechanism of non-uniform removal of composite materials by multiphysics coupling polishing method","authors":"Yan Gu ,&nbsp;Huibo Zhao ,&nbsp;Jieqiong Lin ,&nbsp;Xiaoqin Zhou ,&nbsp;Yuan Xi ,&nbsp;Yinghuan Gao ,&nbsp;Tianyu Gao ,&nbsp;Xiaoming Zhang","doi":"10.1016/j.jmatprotec.2025.118841","DOIUrl":"10.1016/j.jmatprotec.2025.118841","url":null,"abstract":"<div><div>The non-uniform characteristics of SiCp/Al are one of the reasons why it is difficult to process, which leads to surface and sub-surface damage and non-uniform removal of SiCp/Al after polishing. Introducing impact effects through the vibration field to improve the non-uniform removal problem in SiCp/Al machining has been proven effective. However, the mechanisms of the effects of the vibration field on rheological properties and the generation of impact effects are still unclear. Therefore, the non-resonant vibration-assisted wheeled magnetorheological polishing (NVWMRP) method is used to process SiCp/Al, the mechanism of the coupling field (magnetic field, vibration field, and flow field) on the rheological characteristics of magnetorheological polishing fluid (MRPF) is analysed by simulation and experiment. The vibration field promotes the viscous flow of MRPF, and the viscous wave is the main reason for the impact effect. Based on the rheological test results, the polishing force model in the multi-physics coupling environment is established. The SiCp/Al polishing experiment verifies the theory's correctness and explores the polishing process. NVWMRP has a positive significance in reducing the height of the SiCp/Al step. The surface roughness Sa is reduced to 112 nm. This study explains the mechanism of impact effect and provides guidance for applying vibration field-assisted machining technology in magnetorheological polishing and improving the processability of composites.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118841"},"PeriodicalIF":6.7,"publicationDate":"2025-04-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815410","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Microstructure evolution, composition distribution, and crack formation mechanisms of SS 316L/IN718 graded materials fabricated by laser directed energy deposition","authors":"Zongyu Ma ,&nbsp;Weiwei Liu ,&nbsp;Wanyang Li ,&nbsp;Jianrong Song ,&nbsp;Huanqiang Liu ,&nbsp;Zhenxin Lv ,&nbsp;Tandong Wang ,&nbsp;Guangda Hu ,&nbsp;Shitong Peng ,&nbsp;Fengtao Wang ,&nbsp;Yue Zhao ,&nbsp;Hongchao Zhang","doi":"10.1016/j.jmatprotec.2025.118843","DOIUrl":"10.1016/j.jmatprotec.2025.118843","url":null,"abstract":"<div><div>The preparation of functionally graded materials (FGMs) via laser directed energy deposition (LDED) involves the coupling of multiple material parameters, the mechanisms of microstructural evolution and composition distribution under non-equilibrium solidification conditions, and the formation mechanisms of defects during the deposition process, which remain critical scientific challenges to be addressed. Taking the SS 316 L/IN718 material system as an example, this study establishes a multiphase, multicomponent fluid model and a thermo-mechanical coupling simulation framework. Combined with microstructural, crystallographic characterization, and microhardness analysis, it systematically investigates the microstructural transitions, composition distribution, and crack formation mechanisms under a 25 wt% compositional gradient condition. The study reveals that as the deposition layers transition from 100 % SS 316 L to 100 % IN718, the microstructure undergoes a discontinuous change from fine columnar and cellular crystals to coarse columnar and short dendritic crystals. This evolution is jointly influenced by variations in local temperature gradients and uneven solute distribution. Temperature accumulation and differences in the materials' thermal properties enhance molten pool stirring and remelting dilution effects, leading to significant segregation of solute elements (e.g., Nb, Mo). This further reduces the local solidification rate and destabilizes the solid-liquid interface. Cracks are primarily concentrated in the 50 % SS 316 L/50 % IN718 and 25 % SS 316 L/75 % IN718 gradient layers, attributed to liquation cracking caused by local compositional segregation, thermal stress concentration, and the presence of brittle carbides. Thermo-mechanical coupled simulations further confirm that the residual tensile stress is highest in the 25 % SS 316 L/75 % IN718 and 100 % IN718 gradient layers, making them the primary regions for crack initiation. This study proposes a comprehensive analytical method suitable for multi-material additive manufacturing (AM), providing theoretical guidance for compositional distribution regulation, microstructural design, and crack suppression in FGMs.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118843"},"PeriodicalIF":6.7,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815408","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Advancing near-infrared and blue hybrid laser welding: Energy efficiency and microstructural refinement in Al-Mg-Si dissimilar joints","authors":"Q.L. Zhu ,&nbsp;J.M. Yu ,&nbsp;C. Xu ,&nbsp;X. Li ,&nbsp;Z.H. Zhang ,&nbsp;Z.R. Hu ,&nbsp;X.N. Wang ,&nbsp;H. Nagaumi","doi":"10.1016/j.jmatprotec.2025.118842","DOIUrl":"10.1016/j.jmatprotec.2025.118842","url":null,"abstract":"<div><div>The integration of near-infrared (NIR) and blue laser welding technologies presents a promising approach to address the inherent challenges faced by traditional welding methods, particularly when applied to aluminum alloys. This study investigates the effects of NIR-blue hybrid laser welding on the microstructural evolution and mechanical properties of dissimilar Al-Mg-Si alloys welded joints, comparing different power configurations: 1700 W NIR, 1200 W NIR+ 500 W blue, and 1700 W NIR + 500 W blue. The results showed that the introduction of blue laser significantly improved energy absorption efficiency due to the higher absorption rate of aluminum alloys at blue laser wavelengths. The hybrid laser welding minimized keyhole-induced porosity by improving molten pool stability and reducing bubble entrapment. In addition, the appropriate hybrid laser power will improve the yield strength and ductility of the joints, which is attributed to the simultaneous enhancement of multiple strengthening mechanisms. The hybrid laser configuration promoted higher dislocation densities and refined precipitation phases, contributing to improved hardness, strength and ductility. The hybrid laser welding process, particularly the 1200NIR+ 500Blue joint, demonstrated an enhanced solidification rate, a higher nucleation site density, and a reduced grain nucleation radius, all of which facilitated the development of a finer grain structure due to the optimized energy input. However, excessive NIR laser power will weaken the grain-refining effect of the blue laser, leading to grain coarsening. The findings provide critical insights that contribute to the advancement of NIR-blue hybrid laser welding technologies for high-performance manufacturing applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118842"},"PeriodicalIF":6.7,"publicationDate":"2025-04-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800438","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Analysis of arc rotation characteristics in magnetically impelled arc butt welding based on Lorentz force","authors":"Chengyin Liu ,&nbsp;Qi Sun ,&nbsp;Xiaojun Tang ,&nbsp;Yujie Tao ,&nbsp;Haoyu Kong ,&nbsp;Yiheng Liu ,&nbsp;Yibo Liu ,&nbsp;Qingjie Sun","doi":"10.1016/j.jmatprotec.2025.118837","DOIUrl":"10.1016/j.jmatprotec.2025.118837","url":null,"abstract":"<div><div>Magnetically impelled arc butt (MIAB) welding is a cutting-edge joining method developed specifically for tubular components, mainly used in the automotive industry. Arc rotation velocity is an important process parameter which affects welding quality. However, there is a lack of a simple and efficient velocity acquisition method that does not interfere with the welding process. In this paper, the characteristics of arc rotation in magnetically impelled arc butt welding are analyzed from the perspective of Lorentz force for the first time, and a potential simple and efficient velocity acquisition method based on voltage waveform is proposed. The results show that the voltage is different due to the uneven distribution of magnetic flux density on the circumference of the tube end and the different deflection amplitude of arc under different magnetic flux density. Therefore, the periodicity of the voltage waveform is corresponded to the arc rotation. The transmission of plasma in the rotating arc is maintained by collision ionization of electrons and neutral particles. With the increase of exciting current, the arc deflection amplitude and voltage increase, resulting in more heat input being distributed into the gap region, which is conducive to the occurrence of collision ionization and the increase of arc rotation velocity (from 26.2 m/s to 36.2 m/s), the melting uniformity of tube end is improved effectively, and the difference of mechanical properties between the top and bottom of the joint is also reduced.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118837"},"PeriodicalIF":6.7,"publicationDate":"2025-04-04","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800436","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"3D weaving path optimization for enhanced surface quality in wire arc-based directed energy deposition","authors":"Chan Kyu Kim ,&nbsp;Gitae Park ,&nbsp;Dae Won Cho ,&nbsp;Chang-young Oh ,&nbsp;Dong-jin Oh ,&nbsp;Seolbin Jeong ,&nbsp;Young Tae Cho ,&nbsp;Seok Kim ,&nbsp;Bo Wook Seo ,&nbsp;Chang Jong Kim ,&nbsp;Sang Woo Song","doi":"10.1016/j.jmatprotec.2025.118838","DOIUrl":"10.1016/j.jmatprotec.2025.118838","url":null,"abstract":"<div><div>Wire arc-based directed energy deposition (DED) is a highly productive additive manufacturing (AM) technique; however, excessive heat input often results in distortion and irregular bead geometry, leading to increased surface waviness and necessitating extensive post-processing. To address these challenges, this study introduces a novel 3D weaving path aimed at enhancing wetting behavior and minimizing micro-scale waviness in wire arc-based DED. The weaving motion promotes metal spreading by adjusting the wetting area, thereby reducing the contact angle and improving surface smoothness. High-speed imaging and computational fluid dynamics (CFD) simulations were utilized to investigate molten metal behavior during deposition. Experimental results revealed that the 3D weaving path reduces surface waviness by more than 70 % compared to conventional stringer paths, significantly lowering the required machining depth. Additionally, mechanical property evaluations confirmed that the proposed approach maintains consistent hardness and tensile strength, ensuring structural integrity. These findings demonstrate the potential of 3D weaving path technology to enhance the efficiency and precision of large-scale metal AM, reducing post-processing demands and improving manufacturability.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118838"},"PeriodicalIF":6.7,"publicationDate":"2025-04-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800440","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}