Journal of Materials Processing Technology最新文献

Mitigating hydrogen embrittlement in 2205 duplex stainless steel through ultrasonic surface rolling post-treated laser peening 超声波表面轧制后处理激光强化对2205双相不锈钢氢脆的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-29 DOI: 10.1016/j.jmatprotec.2026.119236

Emmanuel Agyenim-Boateng , Shu Huang , Jie Sheng , Yufei Hou , Chaojun Zhao , Qinqing Sha , Jinjin Wen , Shuai Zhang , Yutang Qi , Zhipeng Tan , Mingliang Zhu

Although Laser shock peening (LP) has been used to significantly mitigate hydrogen embrittlement (HE) in alloys, it has been limited by challenges such as a thin layer of relatively discrete surface grains, as well as increased surface roughness, which limits its anti-HE effects. Therefore, ultrasonic surface rolling post-treated laser peening (ULP), which generates a gradient microstructure on the surface of alloys through a combination of ultrasonic surface rolling process (USRP) and LP, was used in this study to improve the hydrogen-induced plasticity loss resistance of 2205 duplex stainless steel. The microstructural evolution, mechanical properties, and resistance to hydrogen-induced plasticity loss of 2205 duplex stainless steel treated by LP, USRP, and ULP were comparatively analyzed. The results show that ULP achieves a significantly higher residual compressive stress than individual LP or USRP treatments. ULP also significantly improves surface roughness, leads to more effective grain refinement with complex grain boundaries, and forms a deeper nanogradient structure on the surface. Additionally, the ULP-induced beneficial microstructural features, such as uniformly distributed high-density dislocations, complex duplex structures, etc., synergistically hinder the migration of hydrogen atoms. This significantly improves the mechanical properties and the hydrogen-induced plasticity loss resistance of 2205 duplex stainless steel. The application of ULP provides new opportunities for expanding the use of surface deformation-strengthening technologies to prevent HE in alloys.

尽管激光冲击强化（LP）已被用于显著减轻合金中的氢脆（HE），但它受到诸如相对离散的表面晶粒薄层以及表面粗糙度增加等挑战的限制，这些挑战限制了其抗氢脆效果。因此，本研究采用超声表面轧制后处理激光强化（ULP），通过超声表面轧制工艺（USRP）和LP相结合，在合金表面产生梯度组织，以提高2205双相不锈钢的抗氢致塑性损失性能。对比分析了LP、USRP和ULP处理2205双相不锈钢的组织演变、力学性能和抗氢致塑性损失性能。结果表明，与单独的LP或USRP处理相比，ULP处理获得了更高的残余压应力。ULP还显著提高了表面粗糙度，在复杂晶界下更有效地细化晶粒，并在表面形成更深的纳米梯度结构。此外，ulp诱导的有利微观结构特征，如均匀分布的高密度位错、复杂的双相结构等，协同阻碍了氢原子的迁移。这显著提高了2205双相不锈钢的力学性能和抗氢致塑性损失性能。ULP的应用为扩大表面变形强化技术的应用提供了新的机会，以防止合金中的HE。

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引用次数: 0

Microstructure and property regulation of TiN-reinforced IN718 composite coatings via ultrasonic vibration – Manufactured by laser directed energy deposition 激光定向能沉积制备tin增强IN718复合涂层的超声振动组织与性能调控

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-29 DOI: 10.1016/j.jmatprotec.2026.119234

Huakai Mao , Long Huang , Zengyan Lv , Tongxin Wang , Haitao Duan , Quanli Luo , Xiang Yao , Nian Liu , Yuqi Peng , Qingsong Mei , Guodong Zhang

TiN-reinforced IN718 composite coatings were prepared using ultrasonic vibration assisted laser directed energy deposition. A new concept of “Seed & Root”-shaped precipitated microstructure was proposed, and the phase composition including Al₂O₃, TiO₂, TiN, MX phase and Laves/γ eutectic phase as well as the morphological evolution law of this microstructure were verified. TiN content and ultrasonic vibration have impacts on the precipitation proportion and uniformity of the precipitated phases. The mechanical properties of the coatings can be regulated by adjusting TiN content, the maximum improvements achieved are 30.9 % in microhardness, 69.7 % in yield strength, and a 47.7 % reduction in wear volume. Due to changes in the morphology and content of the second phase, the wear mechanism of the coatings changes under different TiN addition rates. Ultrasonic vibration exerts a positive effect on the corrosion resistance of the coatings. For coatings with the same TiN addition rate, the corrosion resistance can be enhanced by up to 4.3 times at maximum. The changes in coating properties are mainly reflected in the contributions of solid solution strengthening and second phase strengthening. Ultrasonic vibration promotes solid solution strengthening, while TiN content mainly affects the intensity of second phase strengthening. Ultrasonic waves mainly affect the nucleation rate and molten pool energy through cavitation effect and acoustic streaming effect, thereby regulating the microstructure and properties of the coatings. However, an excessively high TiN addition rate will intensify the attenuation of ultrasonic waves, which in turn has an adverse impact on some properties of the coatings.

采用超声振动辅助激光定向能沉积法制备了tin增强IN718复合涂层。提出了“种子&根”型析出组织的新概念，验证了该组织的相组成包括Al2O3、TiO2、TiN、MX相和Laves/γ共晶相，并验证了该组织的形态演化规律。TiN含量和超声振动对析出相的析出比例和均匀性有影响。通过调整TiN含量可调节涂层的力学性能，显微硬度提高30.9 %，屈服强度提高69.7% %，磨损体积减小47.7 %。由于第二相的形态和含量的变化，不同TiN添加量下涂层的磨损机理发生了变化。超声振动对涂层的耐蚀性有积极的影响。在TiN添加速率相同的情况下，涂层的耐蚀性最高可提高4.3倍。涂层性能的变化主要体现在固溶强化和第二相强化的贡献上。超声振动促进固溶强化，而TiN含量主要影响第二相强化强度。超声波主要通过空化效应和声流效应影响成核速率和熔池能量，从而调节涂层的组织和性能。然而，过高的TiN添加率会加剧超声波的衰减，从而对涂层的某些性能产生不利影响。

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引用次数: 0

In-situ EBSD investigation of the yield ratio reduction and ductility enhancement mechanisms in laser powder bed fusion Al–Fe–Cr–Ni–V high-entropy alloy 激光粉末床熔合Al-Fe-Cr-Ni-V高熵合金屈服比降低和延性增强机理的原位EBSD研究

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-29 DOI: 10.1016/j.jmatprotec.2026.119233

Zhonghan Yu , Wenjuan Xing , Xianke Li , Changyi Liu , Hongwei Zhao

Optimizing the yield ratio and ductility is essential for improving mechanical adaptability and structural reliability in applications spanning biomedical devices, aerospace structures, and flexible electronics. In this study, AlFeCrNiV high-entropy alloys (HEAs) were fabricated via laser powder bed fusion (LPBF), and the effects of substrate temperature (348 and 573 K) and subsequent aging time (6, 12, 48, and 120 h) on microstructural evolution and tensile properties were systematically investigated. The 348 K-fabricated alloy exhibited finer grains, higher residual stress, and greater dislocation density than that 573 K-fabricated, resulting in higher yield strength (YS=680.2 MPa) and ultimate tensile strength (UTS=902.7 MPa), but lower total elongation to failure (30.5 %). During aging, the 348 K series developed a higher volume fraction of BCC precipitates. After 120 h of aging, the 348 K-fabricated alloy maintained a high UTS (920.8 MPa), while its YS decreased to 474 MPa and elongation increased to 36.2 %, thus achieving a desirable combination of a low yield ratio and improved ductility. In-situ EBSD tensile testing and TEM analysis revealed that finely BCC precipitates act as effective barriers to dislocation motion, promote dislocation storage and multiplication, and significantly improve strain-hardening capability. Additionally, these precipitates induce localized lattice rotation and facilitate the formation of refined subgrain-scale deformation-coordination units, effectively suppressing strain localization. The concurrent reduction in yield ratio and improvement in ductility is thus achieved through the synergistic regulation of dislocation density and BCC precipitation. This study elucidates the intrinsic process–microstructure–property relationships in LPBF-fabricated HEAs and provides a framework for microstructure-driven mechanical optimization.

优化屈服比和延展性对于提高生物医学设备、航空航天结构和柔性电子等应用的机械适应性和结构可靠性至关重要。本研究采用激光粉末床熔合法制备了AlFeCrNiV高熵合金（HEAs），系统研究了衬底温度（348和573 K）和时效时间（6、12、48和120 h）对合金组织演变和拉伸性能的影响。与573 k合金相比，348 k合金的晶粒更细，残余应力更高，位错密度更大，屈服强度（YS=680.2 MPa）和极限抗拉强度（UTS=902.7 MPa）更高，但总断裂伸长率（30.5 %）更低。在时效过程中，348 K系列的BCC析出物体积分数较高。时效120 h后，348 k制备的合金仍保持较高的UTS(920.8 MPa)， YS降至474 MPa，伸长率提高至36.2% %，实现了低屈服比和高延展性的完美结合。原位EBSD拉伸试验和TEM分析表明，细小的BCC沉淀有效地阻碍了位错的运动，促进了位错的储存和增殖，显著提高了应变硬化能力。此外，这些析出物诱导局部晶格旋转，促进亚晶粒尺度变形配位单元的形成，有效抑制应变局部化。因此，通过位错密度和BCC析出的协同调节来实现屈服比的降低和延性的提高。本研究阐明了lpbf制造HEAs的内在工艺-微结构-性能关系，并为微结构驱动的力学优化提供了框架。

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引用次数: 0

Ultra-smooth surface of RB-SiC generated by a piezo-Fenton chemical mechanical polishing with high material removal rate 采用压电- fenton化学机械抛光制备的RB-SiC超光滑表面，材料去除率高

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-29 DOI: 10.1016/j.jmatprotec.2026.119235

Haoran Liu , Yikai Zang , Zhi Wang , Xiaoyang Jiang , Jianning Chu , Jianguo Zhang , Jianfeng Xu , Junfeng Xiao

Due to significant differences in properties of two-phase material, it is very difficult to obtain high-quality surface of RB-SiC. Reducing the hardness difference of two-phase materials and suppressing the formation of phase boundary steps are the keys to achieve a low-damage and super-smooth surface of RB-SiC. In the study, piezo-Fenton oxidation was introduced to develop a novel chemical mechanical polishing (CMP). Driven by compressive stress and friction between the polishing pad and workpiece, the surface polarization of bismuth ferrite nanoparticles (BiFeO₃) in the slurry induced a persistently stable Fenton-like reaction. The optimal slurry consisted of diamond micropowder, hydrogen peroxide, bismuth ferrite, silica sol, citric acid and deionized water achieved the ultra-smooth surface of RB-SiC. Surface roughness (Sa) was 0.887 nm over an area of

437 \times 437 {μm}^{2}

. The Sa value of 0.158 nm was obtained in SiC phases (40 × 40 μm²), while the thickness of the damage layer was 2.993 nm. The material removal rate reached a high of 5.001 μm/h. The CMP mechanism was elucidated by X-ray photoelectron, Raman and infrared spectroscopy, which shows that strong oxidizing ability of hydroxyl radicals generated relatively soft oxides on the surfaces of SiC and Si phase, with reduced the hardness difference between the two-phase materials. At the same time, diamond abrasive directly removed the oxide layer covering the material surface without damaging the matrix material. The novel CMP on RB-SiC provided new insights to gain ultra-smooth with high material removal rate for multiphase materials with soft matrix and hard particles.

由于两相材料的性能差异很大，很难获得高质量的RB-SiC表面。减小两相材料的硬度差和抑制相边界台阶的形成是实现RB-SiC低损伤超光滑表面的关键。本研究将压电芬顿氧化技术引入到化学机械抛光（CMP）的研究中。在抛光垫与工件之间的压应力和摩擦的驱动下，铋铁氧体纳米颗粒（BiFeO3）在料浆中的表面极化诱导了持续稳定的类芬顿反应。由金刚石微粉、双氧水、铁酸铋、硅溶胶、柠檬酸和去离子水组成的最佳浆料实现了RB-SiC的超光滑表面。表面粗糙度（Sa）为0.887 nm，面积为437×437μm2。SiC相（40 × 40 μm2）的Sa值为0.158 nm，损伤层厚度为2.993 nm。材料去除率高达5.001 μm/h。通过x射线光电子、拉曼和红外光谱对CMP机理进行了分析，结果表明羟基自由基具有较强的氧化能力，在SiC和Si相表面生成了较软的氧化物，减小了两相材料之间的硬度差。同时，金刚石磨料直接去除覆盖在材料表面的氧化层，而不损伤基体材料。基于RB-SiC的新型CMP为获得具有软基体和硬颗粒的多相材料的超光滑和高材料去除率提供了新的见解。

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引用次数: 0

Liquid-bridge regulation in femtosecond laser-assisted meniscus-confined electrodeposition 飞秒激光辅助半月板约束电沉积中的液桥调节

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-29 DOI: 10.1016/j.jmatprotec.2026.119237

Wanfei Ren , Hao Jiang , Wanfei Ren , Zhaoqiang Zou , Ningqian Tang , Pingmei Ming

Complex metal microstructures hold significant application potential in aerospace and biomedical engineering, yet their fabrication is hindered by critical challenges, particularly in achieving ultra-precision machining and realizing precise regulation of structural contours and surface morphologies at the micrometer scale. To address these issues, this study proposes an innovative femtosecond laser-assisted liquid-bridge regulation strategy for the high-quality and regulable fabrication of metal microstructures via electrodeposition. The core scientific advantage of this approach lies in its utilization of the femtosecond laser-induced photothermal effect, which enables active and non-contact regulation of the liquid-bridge contour a key breakthrough for precise regulation over the dimensions of deposited structures. Leveraging this regulable liquid-bridge regulation strategy, a variety of complex three-dimensional (3D) metal microstructures have been successfully fabricated. Microscopic characterization confirms that the fabricated microstructures possess dense interiors free of macroscopic defects; furthermore, the in-situ formation of nanocrystals and nanotwins endows these structures with excellent mechanical properties. This work provides a novel technical route for the dynamic regulation of electrodeposited structure dimensions, thereby substantially advancing the manufacturing capacity for complex metal microstructures and offering valuable insights for the broader research community in related fields.

复杂的金属微结构在航空航天和生物医学工程中具有重要的应用潜力，但它们的制造受到关键挑战的阻碍，特别是在实现超精密加工和实现微米尺度上结构轮廓和表面形态的精确调节方面。为了解决这些问题，本研究提出了一种创新的飞秒激光辅助液桥调节策略，用于通过电沉积高质量和可调节的金属微结构制造。该方法的核心科学优势在于它利用了飞秒激光诱导的光热效应，使液桥轮廓的主动和非接触调节成为精确调节沉积结构尺寸的关键突破。利用这种可调节的液桥调节策略，已经成功地制造了各种复杂的三维（3D）金属微结构。微观表征证实，制备的微结构具有致密的内部，没有宏观缺陷；此外，纳米晶和纳米孪晶的原位形成使这些结构具有优异的力学性能。这项工作为电沉积结构尺寸的动态调节提供了一条新的技术路线，从而大大提高了复杂金属微结构的制造能力，并为相关领域的广泛研究提供了有价值的见解。

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引用次数: 0

In situ surface rejuvenation and plasticity enhancement of Zr-based bulk metallic glass by high-speed cutting 高速切削zr基大块金属玻璃的原位表面回春及塑性增强

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-29 DOI: 10.1016/j.jmatprotec.2026.119232

Feng Ding , Pingjun Tao , Tao Zhang , Zijian Lai , Hongye Wu , Jun Wang , Lijuan Zheng , Xi Shen , Chengyong Wang

Zirconium-based (Zr-based) bulk metallic glasses (BMGs) are promising structural materials, but their application is hindered by their intrinsic brittleness, which arises from shear localization. This work presents an in situ surface engineering strategy that simultaneously shapes and functionally enhances Zr-based BMGs by harnessing the strong thermomechanical coupling associated with high-speed cutting. It is demonstrated that even at cutting speeds up to1600 m/min, high-speed cutting kinetically suppresses crystallization while spontaneously inducing structural rejuvenation in the machined subsurface. Multiscale characterization reveals that this rejuvenated state, characterized by reduced atomic ordering and increased free volume, drives a fundamental transition in the mechanical deformation mechanism: the volume of the shear transformation zone is refined, promoting a shift from highly localized shear banding to more homogeneous plasticity. Consequently, the engineered subsurface exhibits dramatically enhanced damage tolerance, with both plastic instability strain and energy absorption capacity prior to failure doubled compared to the as-cast state. This study establishes clear process–structure–property relationships, demonstrating that high-speed cutting is a versatile in situ manufacturing platform for tailoring the functional surface properties of BMGs. This approach bridges geometric shaping with property engineering, offering an efficient route for fabricating high-performance BMG components for advanced engineering applications.

锆基大块金属玻璃（Zr-based bulk metallic glass, bmg）是一种很有前途的结构材料，但由于剪切局部化而产生的固有脆性阻碍了其应用。这项工作提出了一种原位表面工程策略，通过利用与高速切削相关的强热-机械耦合，同时塑造和增强zr基bmg的功能。结果表明，即使在高达1600 m/min的切削速度下，高速切削在动力学上抑制了结晶，同时自发地诱导了加工亚表面的结构再生。多尺度表征表明，这种以原子有序度降低和自由体积增加为特征的恢复状态，推动了力学变形机制的根本转变：剪切转变区的体积被细化，促进了从高度局部剪切带向更均匀塑性的转变。因此，与铸态相比，工程亚表面表现出显著增强的损伤容忍度，破坏前的塑性不稳定应变和能量吸收能力都增加了一倍。该研究建立了清晰的工艺-结构-性能关系，证明高速切削是一种多功能的原位制造平台，可用于定制bmg的功能表面特性。这种方法将几何形状与性能工程相结合，为制造高性能的BMG组件提供了有效的途径，用于先进的工程应用。

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引用次数: 0

High-energy metal ion-peening of brazed diamond tools and assessing its scope to enhance grinding performance 钎焊金刚石工具的高能金属离子强化及其对磨削性能的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-28 DOI: 10.1016/j.jmatprotec.2026.119239

Prakashraj E., Amitava Ghosh

In the present study, a novel ion-peening technique has been attempted to alleviate brazing process-induced tensile residual stress developed within the diamond-filler bonding region of brazed diamond tools. High brazing temperature and significant mismatch in the thermo-mechanical properties of the diamond, filler alloy, and steel substrate are the factors causing such stresses, which get pronounced during the cooling cycle, often deleteriously leading to microcrack formation in the diamond-filler interfacial region. Such a crack even propagates into the diamond grit, leading to premature grit failure during grinding. To overcome this challenge, a typical “etching” cycle of high-power impulse magnetron sputtering (HiPIMS) process was improvised to “ion-peening” in the present work under high substrate bias and applied to brazed diamond tools. During peening, the cloud of ions in the plasma was predominantly populated by metal ions (Cr-ion), preferring to mere inert gas ions, so that enhanced momentum transfer is realised. Micro-sized diamonds were brazed with C45 steels by Ni-Cr based filler alloy to produce single-grit specimens and miniature diamond tools, and subsequently subjected them to ion-peening. X-ray diffraction (XRD) and Raman spectroscopic analyses suggest a significant reduction in the brazing-induced residual stress within the carbide interlayer (+2022 MPa to +1023.5 MPa) due to ion peening. Within the diamond near bonding level, this reduction was from + 45.48 MPa to −292.21 Pa. Single-grit studies reveal an approximate increase of 85 % joint strength in ion-peened specimens. On the other hand, a maximum reduction of 35–40 % in the number of grit failures is recorded on peened diamond wheels during grinding. Significant reduction in tensile residual stress and partial healing of micro-cracks are identified to be the underlying mechanisms of such enhanced joint strength. The findings suggest that metal ion-peening could be a potential post-treatment process to produce brazed diamond tools with enhanced tool life and overall performance during grinding.

在本研究中，一种新的离子喷丸技术已经被尝试用来减轻钎焊过程中产生的残余拉伸应力，这些应力产生在钎焊金刚石工具的金刚石-填料结合区域。高钎焊温度和金刚石、钎料合金和钢基体的热-机械性能的显著不匹配是产生这种应力的因素，这种应力在冷却循环中变得明显，往往导致金刚石-钎料界面区域形成有害的微裂纹。这种裂纹甚至扩展到金刚石砂粒中，导致磨削过程中砂粒过早失效。为了克服这一挑战，本研究将大功率脉冲磁控溅射（HiPIMS）工艺的典型“蚀刻”周期改进为高衬底偏压下的“离子喷炼”，并应用于钎焊金刚石工具。在喷射过程中，等离子体中的离子云主要由金属离子（Cr-ion）填充，而不是惰性气体离子，因此实现了增强的动量传递。采用Ni-Cr基填充合金钎焊C45钢制备微粒度金刚石试样和微型金刚石工具，并对其进行离子强化处理。x射线衍射（XRD）和拉曼光谱分析表明，由于离子强化，钎焊诱导的碳化物夹层内残余应力（+2022 MPa至+1023.5 MPa）显著降低。在金刚石接近键合的水平，这一降低从+ 45.48 MPa到−292.21 Pa。单粒研究表明，离子喷丸试样的节理强度约增加85 %。另一方面，在磨砂过程中，经喷砂处理的金刚石砂轮的砂粒失效次数最大减少了35-40 %。拉伸残余应力的显著降低和微裂纹的部分愈合被认为是这种增强接头强度的潜在机制。研究结果表明，金属离子喷丸可能是一种潜在的后处理工艺，可以提高钎焊金刚石工具的使用寿命和磨削过程中的整体性能。

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引用次数: 0

A novel polyvinyl alcohol/guar gum hydrogel-based fluid abrasive for abrasive flow machining with enhanced processing performance 一种新型聚乙烯醇/瓜尔胶水凝胶液体磨料，用于磨料流加工，提高了加工性能

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-28 DOI: 10.1016/j.jmatprotec.2026.119238

Jingyi Liu , Xiaoyun Bai , Wenhui Li , Xiuhong Li , Xiaoming Yin , Shengqiang Yang , Kun Li

Selective laser melting (SLM)-fabricated components often exhibit high surface roughness and inherent surface defects, necessitating efficient post-processing. Hydrogel-based fluid abrasives are environmentally friendly alternatives for abrasive flow machining (AFM). However, traditional hydrogel matrices are generally based on polysaccharide polymers and suffer from limited mechanical strength and poor thermal stability, leading to water loss during processing, which restricts their practical application. To overcome these limitations, this study develops a novel polyvinyl alcohol-guar gum (PVA-GG) hydrogel-based fluid abrasive for the AFM of SLM-fabricated surfaces. In this system, the PVA provides mechanical load-bearing capacity, while the GG enhances viscoelasticity, jointly forming a tightly entangled network structure. The fluid abrasive was systematically characterized in terms of viscoelasticity, self-healing properties, thermal stability, and degradability, and its process performance was evaluated during the finishing of SLM-fabricated GH4169 alloy flow channels. The PVA-GG fluid abrasive shows significantly higher viscosity and modulus, with a weight loss of only 9.09 % below 100 °C. It also demonstrates remarkable self-healing properties and degradability. After AFM processing, the surface roughness (Ra) of the workpiece can be reduced by 90 %, and the material removal rate (MRR) reaches 0.43 mm³ /min, outperforming conventional fluid abrasives. Material removal in PVA-GG fluid abrasive is achieved through the combined actions of sliding, plowing, and micro-cutting. This study provides an efficient, sustainable, and mechanism-based approach for the precision surface finishing of SLM-fabricated components.

选择性激光熔化（SLM）制造的部件通常具有高表面粗糙度和固有的表面缺陷，需要有效的后处理。水凝胶基流体磨料是磨料流加工（AFM）的环保替代品。然而，传统的水凝胶基质一般以多糖聚合物为基础，机械强度有限，热稳定性差，导致加工过程中水分流失，制约了其实际应用。为了克服这些限制，本研究开发了一种新型的聚乙烯醇-瓜尔胶（PVA-GG）水凝胶基流体磨料，用于slm制造表面的AFM。在该体系中，PVA提供机械承载能力，而GG增强粘弹性，共同形成紧密纠缠的网络结构。从粘弹性、自愈性、热稳定性和可降解性等方面对该流体磨料进行了系统表征，并在slm制备的GH4169合金流道的精加工过程中对其工艺性能进行了评价。PVA-GG流体磨料的黏度和模量显著提高，在100℃下的失重率仅为9.09 %。它还具有显著的自愈性和可降解性。AFM加工后，工件表面粗糙度（Ra）可降低90 %，材料去除率（MRR）达到0.43 mm³ /min，优于传统的流体磨料。PVA-GG流体磨料的材料去除是通过滑动、犁耕和微切削的共同作用来实现的。本研究提供了一种高效、可持续和基于机制的方法，用于slm制造部件的精密表面加工。

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引用次数: 0

Fast shot speed–dependent defect evolution in high-pressure die casting: Coupled roles of externally solidified crystals and cavity-formed α-Al 高压压铸中快射速缺陷演化：外部凝固晶体与空腔形成α-Al的耦合作用

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-23 DOI: 10.1016/j.jmatprotec.2026.119228

Lei Liu , Guantao Wang , Kai Zhao , Kaiyang Li , Yanqiang Li , Huanyue Zhang , Tao Zhang , Ying Fu , Zhirou Zhang , Enyu Guo , Huijun Kang , Zongning Chen , Jianru Fang , Tongmin Wang

Microstructural inhomogeneity and associated mechanical property fluctuations are inherent challenges in high-pressure die casting (HPDC), with origins difficult to elucidate due to coupled solidification and melt flow. In this study, the microstructural response of an HPDC AlSi10MnMg alloy to varying fast shot speeds was investigated using a TiB₂-assisted strategy to modify nucleation behavior in the shot sleeve and die cavity, enabling decoupling of the roles of externally solidified crystals (ESCs) and cavity-formed α-Al ((α-Al)_II) in defect formation. The results show that ESCs exhibit opposite responses to increasing fast shot speed. When ESCs nucleate near the shot sleeve wall, higher fast shot speed reduces ESCs content and size, whereas when ESCs are more uniformly dispersed in the melt, increasing fast shot speed promotes their transport into the die cavity, resulting in increased ESCs content. Under thermal-gradient-dominated solidification in die cavity, increasing fast shot speed leads to an inward shift and widening of segregation bands, accompanied by a reduced porosity volume fraction and increased pore number density. In contrast, when heterogeneous nucleation in the die cavity is promoted by TiB₂ addition, segregation-band position remains stable with band widening, while both porosity volume fraction and pore number density decrease, even though ESCs content increases. These defect evolutions are associated with systematic variations in strength and ductility. This work presents a process-based perspective for defect control in HPDC by decoupling microstructural variables under coupled melt flow and solidification, which may extend to other forming processes where flow and solidification are coupled.

显微组织不均匀性和相关的力学性能波动是高压压铸（HPDC）的固有挑战，由于凝固和熔体流动的耦合，其起源难以阐明。在这项研究中，采用tib2辅助策略，研究了HPDC AlSi10MnMg合金对不同快速射速的微观组织响应，以改变射套和模腔中的形核行为，使外部凝固晶体（ESCs）和腔内形成的α-Al （(α-Al)II）在缺陷形成中的作用解耦。结果表明，ESCs随着快射速度的增加表现出相反的反应。当ESCs在喷丸套壁附近成核时，高的快射速度降低了ESCs的含量和尺寸，而当ESCs在熔体中分布更均匀时，快射速度的增加促进了ESCs向模腔的迁移，从而导致ESCs含量的增加。在热梯度主导的模腔内凝固过程中，随着快射速度的增加，偏析带向内移动和扩大，孔隙体积分数降低，孔隙数密度增加。而当TiB2的加入促进模腔内非均相形核时，尽管ESCs含量增加，但偏析带位置保持稳定，而孔隙体积分数和孔数密度均降低。这些缺陷的演变与强度和延性的系统变化有关。本研究提出了一种基于过程的视角，通过解耦熔体流动和凝固耦合下的微观结构变量来控制高压直流成形过程中的缺陷，这可能扩展到其他流动和凝固耦合的成形过程中。

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引用次数: 0

Morphology evolution and passivation behavior of nickel-based single crystal superalloys in laser and electrochemical hybrid machining 镍基单晶高温合金激光与电化学复合加工的形貌演变及钝化行为

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-21 DOI: 10.1016/j.jmatprotec.2026.119227

Xue Yang , Yao Yao , Hao Tong , Chengjuan Yang , Yong Li , Zhen Yang , Dawei Zhang

Nickel based single crystal superalloys (NBSCs) are widely used in advanced aero-engines owing to their outstanding high-temperature strength, thermal stability, and corrosion resistance. Laser-electrochemical hybrid machining (LECM) is an emerging technique capable of achieving efficient, damage-free machining of difficult-to-machine materials. However, during LECM of NBSCs, the γ/γ′ two-phase structure exhibits phase-selective electrochemical dissolution and non-uniform passivation, leading to position-dependent material removal behavior that compromises the machining accuracy and surface integrity. The LECM based on an optical fiber inserted tubular electrode (LECM-OFTE) is employed to achieve stable coupling of laser and electrolytic energy fields, attaining higher laser transmission efficiency and realizing higher machining efficiency. In this study, the laser-induced passivation mechanisms of NBSC DD6 superalloy are systematically investigated under the LECM-OFTE process. Morphological and compositional analyses reveal the evolution of passive films and their influence on phase-selective dissolution under different laser intensities. Electrochemical measurements further elucidate the growth, breakdown, and recovery behavior of passive layers under hybrid interactions. Based on the experimental and mechanistic analysis, component-scale LECM of DD6 is further demonstrated using a miniaturized coaxial tubular electrode. Under 12.5 wt% NaNO₃ electrolyte and 5 W laser power, 5-mm-deep holes with an aspect ratio of 7 are machined with markedly reduced stray corrosion and tight dimensional repeatability (entrance: 719 ± 50 μm, exit: 773 ± 38 μm at 50 μm/s feed rate), corroborating the critical role of laser-enhanced passivation in enabling high-precision machining.

镍基单晶高温合金以其优异的高温强度、热稳定性和耐腐蚀性被广泛应用于先进的航空发动机中。激光-电化学混合加工（LECM）是一种新兴技术，能够实现对难加工材料的高效、无损伤加工。然而，在NBSCs的LECM过程中，γ/γ '两相结构表现出相选择性电化学溶解和不均匀钝化，导致与位置相关的材料去除行为，从而影响加工精度和表面完整性。采用基于光纤插管电极（LECM- ofte）的LECM实现了激光与电解能量场的稳定耦合，提高了激光传输效率，实现了更高的加工效率。在LECM-OFTE工艺下，系统地研究了NBSC DD6高温合金的激光诱导钝化机理。形貌和成分分析揭示了不同激光强度下钝化膜的演变及其对相选择性溶解的影响。电化学测量进一步阐明了被动层在杂化相互作用下的生长、击穿和恢复行为。在实验和机理分析的基础上，利用小型化的同轴管状电极进一步验证了DD6的组件级LECM。在12.5 wt%的纳米₃电解液和5 W的激光功率下，加工出宽高比为7的5mm深孔，显著降低了杂散腐蚀，尺寸重复性好（在50 μm/s的进给速率下，入口：719 ± 50 μm，出口：773 ± 38 μm），证实了激光增强钝化在实现高精度加工中的关键作用。

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引用次数: 0