Journal of Materials Processing Technology最新文献

Revealing the deposition behavior and bonding mechanisms of friction stir additive manufacturing based on wire-chopping screw press-assisted heating via multi-dimensional material tracing technology 通过多维材料示踪技术揭示了基于丝切螺杆辅助加热的搅拌摩擦增材制造的沉积行为和结合机理

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-06 DOI: 10.1016/j.jmatprotec.2026.119247

Zhipeng Li, Jun Xiao, Shujun Chen, Xingyu Lu, Zhaoyang Yan

Wire-based friction stir additive manufacturing (W-FSAM) faces a persistent challenge in the solid-phase processing community: the hardening of plasticized material after brief pauses, which hinders continuous manufacturing along discontinuous paths and inhibits tool movement. This limitation complicates the characterization of interlayer bonding interfaces. To overcome this issue, FSAM based on wire-chopping screw press-assisted heating (FSAM-WCSP-AH) process is proposed. The material deposition behavior was analyzed by studying the deposition structure inside the sleeve and examining the morphology under varying parameters. Flow behavior was investigated using multi-dimensional material tracer observation (AA2319 deposited onto AA6061 substrate), emergency-stop techniques, and 3D X-ray computed tomography. Interface bonding characteristics were examined through optical microscopy, electron backscatter diffraction, and transmission electron microscopy. The feasibility of continuous manufacturing along discontinuous paths and the bonding performance were validated by depositing a wall structure with unidirectional interlayer paths. The results show that partial particles are transformed into an annular structure inside the tool, then extruded and sheared into either 'massive' or 'filamentary' deposits, exhibiting a ring-like flow pattern in both horizontal and vertical planes. The deposited layer consists of the deposition zone and stirring deposition zone (SDZ). Metallurgical bonding and a localized 'mechanical-interlocking-like' mechanism occur at the advancing-side and retreating-side interfaces of the SDZ. The central SDZ forms a 'composite-like structure,' where the deposited material embeds into the substrate, with refinement rates of 98.5 % for the deposit and 97.5 % for the substrate. These findings clarify the fundamental physical mechanisms in FSAM-WCSP-AH and provide practical insights for addressing clogging-related challenges in similar solid-phase additive processes.

丝基搅拌摩擦增材制造（W-FSAM）在固相加工领域面临着一个持续的挑战：塑化材料在短暂停顿后硬化，这阻碍了沿着不连续路径的连续制造，并抑制了刀具的运动。这一限制使层间键合界面的表征复杂化。为了克服这一问题，提出了基于断线螺旋压辅加热（FSAM- wcsp - ah）工艺的FSAM。通过研究套管内部的沉积结构和不同参数下的形貌，分析了材料的沉积行为。通过多维材料示踪观察（AA2319沉积在AA6061基板上）、紧急停止技术和3D x射线计算机断层扫描来研究流动行为。通过光学显微镜、电子背散射衍射和透射电镜对界面键合特性进行了研究。通过沉积具有单向层间路径的壁结构，验证了沿不连续路径连续制造的可行性和粘接性能。结果表明，部分颗粒在工具内部转变为环状结构，然后挤压和剪切成块状或丝状沉积物，在水平和垂直平面上都表现出环状流动模式。沉积层包括沉积带和搅拌沉积带（SDZ）。冶金结合和局部“机械联锁”机制发生在SDZ的前进面和后退面界面。中心SDZ形成“复合结构”，沉积的材料嵌入基材中，沉积层的精细化率为98.5 %，基材的精细化率为97.5 %。这些发现阐明了FSAM-WCSP-AH的基本物理机制，并为解决类似固相添加剂工艺中与堵塞相关的挑战提供了实用的见解。

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引用次数: 0

Synergistic control of grain orientation and nano-precipitates by process optimization for enhancement of magnetostriction in laser powder bed fusion fabricated Fe-Ga alloy 通过优化工艺协同控制晶粒取向和纳米析出物增强激光粉末床熔合Fe-Ga合金的磁致伸缩性能

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-04 DOI: 10.1016/j.jmatprotec.2026.119245

Xiaokang Yang , Yong Hu , Jiayu Xu , Yubi Gao , Hongfei Zhang , Wei Jiang , Yutian Ding , Haofang Ma , Wenge Zhang , Ze Wang

Fe-Ga alloys are important magnetostrictive materials used in actuators, sensors, and transducers. Laser powder bed fusion (LPBF) enables the fabrication of components with complex geometries and overcomes dimensional constraints, offering a new route for producing advanced magnetostrictive devices. However, the magnetostriction of LPBF-fabricated Fe-Ga alloys remains lower than that of conventionally directionally solidified counterparts, limiting their use in high-performance components. Enhancing the < 100 > texture and inducing nanoscale L6₀ phase precipitation have been identified as effective approaches to improve the magnetostriction. In this study, Fe₈₁Ga₁₉ alloys were fabricated by LPBF, and process design was used to investigate texture evolution and precipitation behavior, aiming to achieve synergistic control of < 100 > texture and L6₀ phase. The effects of key processing variables, including scanning strategy, inter-layer dwell time, and building strategy, were examined under in-situ remelting conditions. Results show that rotating adjacent scanning layers by 67° balances heat accumulation and dissipation, promoting < 100 > ∥BD texture (easy magnetization axis) and increasing the density of nanoscale L6₀ precipitates, which results in a magnetostriction of λ_∥ = 225 ± 7 ppm. Extending the inter-layer dwell time enhances the < 100 > ∥BD texture but reduces L6₀ precipitate density, consequently lowering magnetostriction. Despite the presence of L6₀ phases, samples with hard magnetization directions (<111 > and <110 >) exhibit negligible magnetostriction. In summary, this work provides key insights into process-structure-property relationships in additively manufactured Fe-Ga alloys. It clarifies the mechanisms and processing routes for achieving high-performance magnetostrictive materials and provides theoretical and practical guidance for controlling crystallographic texture and nanoscale precipitation in additive manufacturing.

Fe-Ga合金是用于致动器、传感器和换能器的重要磁致伸缩材料。激光粉末床熔合（LPBF）能够制造复杂几何形状的元件，克服了尺寸限制，为生产先进的磁致伸缩器件提供了新的途径。然而，lpbf制备的Fe-Ga合金的磁致伸缩仍然低于常规定向固化的Fe-Ga合金，这限制了它们在高性能部件中的应用。增强<； 100 >； 织构和诱导纳米级L60相析出是改善磁致伸缩的有效途径。本研究采用LPBF制备Fe81Ga19合金，通过工艺设计研究织构演化和析出行为，以实现<； 100 >； 织构和L60相的协同控制。在原位重熔条件下，考察了扫描策略、层间停留时间和构建策略等关键工艺变量的影响。结果表明，将相邻扫描层旋转67°可以平衡热量的积累和散失，促进了<； 100 >； ∥BD织体（易磁化轴）的形成，增加了纳米级L60析出物的密度，导致λ∥= 225 ± 7 ppm的磁致伸缩。延长层间停留时间增强了<； 100 >； ∥BD织构，但降低了L60沉淀密度，从而降低了磁致伸缩。尽管存在L60相，但具有硬磁化方向（<111 >；和<；110 >）的样品表现出可以忽略不计的磁致伸缩。总之，这项工作为增材制造Fe-Ga合金的工艺-结构-性能关系提供了关键见解。阐明了实现高性能磁致伸缩材料的机理和工艺路线，为增材制造中控制晶体织构和纳米级析出提供了理论和实践指导。

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引用次数: 0

Overcoming electric field non-uniformity in through-mask electrochemical micromachining using regulating electrode 利用调节电极克服过掩膜电化学微加工中的电场不均匀性

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-10 DOI: 10.1016/j.jmatprotec.2026.119259

Xiaochen Yang , Meng Li , Bingze Shang , Huifeng Qiu , Bingnan Liu , Liqun Du

Through-mask electrochemical micromachining (TMEMM) is a key technique for fabricating metal microstructures. However, the electric field edge effect, caused by geometric discontinuities at the edges of the photoresist patterns, is a long-standing challenge that significantly reduces machining uniformity. To address this issue, this paper introduces a regulating electrode into induction electrode TMEMM (IETMEMM) for the first time and proposes a novel method called regulating electrode-assisted IETMEMM (RE-IETMEMM). In RE-IETMEMM, the introduced regulating electrode forms an equipotential body parallel to the induction workpiece electrode. As a result, the electric field edge effect present in both TMEMM and IETMEMM is suppressed. To verify the practicality of this method, theoretical analysis, simulations, and experiments are conducted. Experimental results show that RE-IETMEMM achieves more uniform machining than both TMEMM and IETMEMM, which is consistent with the theoretical and simulation results. Compared with traditional TMEMM, RE-IETMEMM improves the depth uniformity of the microfluidic chip mold, rhombus array, and gear mold by 75.0 %, 66.6 %, and 71.9 %, respectively. Similarly, the line width uniformity of the rhombus array, gear mold, and perforated plate improves by 97.2 %, 92.9 %, and 73.3 %. The consistently high uniformity of these microstructures confirms that RE-IETMEMM is suitable for various types of microstructures. These findings demonstrate the strong potential of RE-IETMEMM for industrial applications.

透膜电化学微加工（TMEMM）是金属微结构加工的一项关键技术。然而，由光刻胶图案边缘的几何不连续引起的电场边缘效应是一个长期存在的挑战，它显著降低了加工的均匀性。为了解决这一问题，本文首次在感应电极TMEMM （IETMEMM）中引入了调节电极，并提出了一种新的方法——调节电极辅助IETMEMM （RE-IETMEMM）。在RE-IETMEMM中，引入的调节电极形成与感应工件电极平行的等电位体。从而抑制了TMEMM和IETMEMM中存在的电场边缘效应。为了验证该方法的实用性，进行了理论分析、仿真和实验。实验结果表明，RE-IETMEMM比TMEMM和IETMEMM加工更均匀，与理论和仿真结果一致。与传统的TMEMM相比，RE-IETMEMM使微流控芯片模具、方阵模具和齿轮模具的深度均匀性分别提高了75.0 %、66.6% %和71.9 %。同样，菱形阵列、齿轮模具和穿孔板的线宽均匀性提高了97.2% %，92.9 %和73.3 %。这些微结构的一致性证实了RE-IETMEMM适用于各种类型的微结构。这些发现证明了RE-IETMEMM在工业应用方面的强大潜力。

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引用次数: 0

Revealing pore elimination and redistribution mechanisms during laser re-melting via in-situ X-ray imaging 通过原位x射线成像揭示激光重熔过程中孔隙消除和重分布机制

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-06 DOI: 10.1016/j.jmatprotec.2026.119250

Muyi Zhou , Heng Gu , Dongxu Cheng , Yongjian Li , Zhaopeng Tong , Lili Qian , Lin Li , Chao Wei , Xudong Ren

Laser re-melting is widely utilized to enhance the densification and surface quality of various components; however, a quantitative mechanistic understanding of transient molten pool dynamics and the resulting transformation of pore distribution remains limited. This study employs in-situ high-speed synchrotron X-ray imaging combined with high-fidelity numerical simulations to systematically compare pore evolution during an initial scan and a subsequent re-melting pass (250 W; 100–500 mm/s). The results demonstrate that re-melting effectively reduces porosity, achieving a 30 % reduction in pore area density at lower speeds—primarily through the suppression of larger pores—and total elimination at 500 mm/s. Quantitative spatial analysis in a region-resolved manner reveals a transition from localized pore clustering toward a more uniform distribution: at 100 mm/s, the Clark–Evans nearest-neighbor index R increased from 0.600 to 0.651, while at 300 mm/s, the transverse index R_x rose from 0.917 to 1.151. Furthermore, re-melting significantly inhibits pore–pore interactions, with the coalescence frequency Γ dropping from over 31 % to as low as 11.54 %, thereby preventing the formation of large and detrimental pore clusters. Mechanistically, numerical simulations show that re-melting produces an elongated molten pool with extended high-temperature-gradient regions. This broader thermal field shifts the melt flow from localized recirculation-dominated motion to stretch-dominated transport, which facilitates the break-up of clusters and promotes a dispersed spatial redistribution. By providing a quantitative framework for pore migration, interaction, and spatial organization, this work offers mechanistic guidance for process optimization to improve the structural reliability and fatigue life of laser-processed components.

激光重熔被广泛用于提高各种零件的致密性和表面质量；然而，对瞬态熔池动力学和由此产生的孔隙分布转变的定量机制理解仍然有限。本研究采用原位高速同步x射线成像结合高保真数值模拟，系统地比较了初始扫描和随后的重熔过程（250 W; 100-500 mm/s）中的孔隙演化。结果表明，重熔有效地降低了孔隙率，在较低的速度下（主要是通过抑制较大的孔隙），孔隙面积密度降低了30 %，在500 mm/s的速度下，孔隙面积密度完全消除。区域分辨的定量空间分析表明，在100 mm/s下，Clark-Evans最近邻居指数R从0.600上升到0.651，在300 mm/s下，横向指数Rx从0.917上升到1.151。此外，重熔显著抑制了孔隙-孔隙相互作用，聚结频率Γ从31 %以上降至11.54 %，从而防止了大而有害的孔隙团簇的形成。在力学上，数值模拟表明，重熔产生了一个细长的熔池，并扩展了高温梯度区域。这种更宽的热场将熔体流动从局部再循环主导的运动转变为拉伸主导的运输，这有利于团簇的破裂和促进分散的空间再分布。通过提供孔隙迁移、相互作用和空间组织的定量框架，该工作为工艺优化提供了机制指导，以提高激光加工部件的结构可靠性和疲劳寿命。

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引用次数: 0

Observation-driven punching simulation using inverse identification of quasi-nonparametric ductile fracture locus 基于准非参数韧性断裂轨迹逆识别的观测驱动冲孔模拟

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-03 DOI: 10.1016/j.jmatprotec.2026.119243

Jin Eguchi , Takashi Matsuno , Yasuhiro Kunii , Kazuyuki Shimizu , Yuichi Matsuki , Toyohisa Shinmiya , Eiji Iizuka

Edge cracking, including delayed fracture, resulting from excessive tensile residual stresses in the punched surfaces of advanced high-strength steel sheets, necessitates accurate characterization to predict failure. However, conventional stress measurement methods, such as X-ray diffraction (XRD), provide only area-averaged values that do not necessarily correlate with edge cracking. Although finite element (FE) simulations can estimate detailed stress distributions, their accuracy is limited by their inability to replicate the geometries of punched surfaces. Therefore, this study introduces a novel observation-driven FE simulation approach to visualize detailed residual stress distributions by accurately replicating punched-hole profiles using the quasi-nonparametric ductile fracture locus (DFL), which is identified using the observed hole geometries and crack propagation behaviors in partially punched sheets. The DFLs for different material strengths and punching clearances were determined by examining the boundary between the state variables of elements along an explicit crack path and those in nonfracture areas. These DFLs differed significantly from those derived using conventional material tests, uniquely capturing the fracture behavior under low stress triaxiality and severe plastic deformation conditions associated with punching. This suggests a fracture mechanism distinct from the typical microvoid coalescence model, which assumes the creation of numerous fracture initiation sites in the submicron microstructure under severe plastic strain. Consequently, FE punching simulations incorporating the obtained DFLs accurately reproduced the punched-hole profiles, and the area-averaged residual stresses were in good agreement with XRD measurements. The proposed technique enables the inverse estimation of residual stress and material parameters from simple geometric measurements, holding considerable industrial potential.

高级高强度钢板冲压表面的拉伸残余应力过大，导致边缘开裂，包括延迟断裂，需要准确的表征来预测失效。然而，传统的应力测量方法，如x射线衍射（XRD），只能提供面积平均值，并不一定与边缘开裂相关。虽然有限元（FE）模拟可以估计出详细的应力分布，但由于无法复制穿孔表面的几何形状，其准确性受到限制。因此，本研究引入了一种新的观察驱动的有限元模拟方法，通过使用准非参数韧性断裂轨迹（DFL）精确复制冲孔轮廓，从而可视化详细的残余应力分布。准非参数韧性断裂轨迹（DFL）是通过观察部分冲孔板的孔几何形状和裂纹扩展行为来识别的。通过考察显裂纹路径上单元状态变量与非断裂区域单元状态变量之间的边界，确定了不同材料强度和冲孔间隙下的dls。这些dfl与使用传统材料测试得出的结果有很大不同，独特地捕捉了与冲压相关的低应力三轴性和严重塑性变形条件下的断裂行为。这表明了一种不同于典型微孔隙聚结模型的断裂机制，后者假设在严重塑性应变下，在亚微米微观结构中产生了许多断裂起裂点。因此，结合所获得的DFLs的有限元冲压模拟准确地再现了冲孔轮廓，并且区域平均残余应力与XRD测量结果吻合良好。所提出的技术能够从简单的几何测量中逆估计残余应力和材料参数，具有相当大的工业潜力。

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引用次数: 0

High-strength Ti/Al joining via in-situ synthesized amorphous interlayer: Processes, microstructure, mechanical properties and mechanism 原位合成非晶间层高强Ti/Al连接：工艺、显微组织、力学性能及机理

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-10 DOI: 10.1016/j.jmatprotec.2026.119260

Xiaobo Li , Xiaochao Liu , Xincheng Wang , Haiying Wen , Tairui Zhang , Fangyong Niu , Lei Shi , Zhonghua Ni

To meet the demand for lightweight structures, Ti/Al dissimilar welding components are in growing demand. However, conventional friction stir lap welding techniques are unsatisfactory for Ti/Al joining due to severe tool wear and limited joint strength. In this study, a vortex flow-based friction stir lap welding (VFSLW) process was employed to mitigate tool wear and achieve high-strength Ti/Al bonding via the in-situ formation of a nanoscale amorphous interlayer. The effects of welding parameters and tool configurations on joint performance were systematically examined. Mechanical testing, microstructural characterization, and theoretical analysis were conducted to elucidate the fundamental bonding mechanisms. A feasible process window was established through welding experiments. It shows that hollow stir pins with 1.8–2.2 mm in length were applicable for VFSLW of 3 mm thick 5083Al plates to Ti-6Al-4V plates. The optimal joint was obtained at a rotation speed of 100 rpm and a welding speed of 15 mm/min with a hollow stir pin of 2.2 mm in length, exhibiting a maximum line load of 484 N/mm. A nanoscale amorphous layer was observed at the Ti/Al interface, which plays a crucial role in enabling excellent joint properties. The formation of this amorphous layer is mainly attributed to weak material flow and relatively low reaction temperatures. This study not only establishes a theoretical framework for controlling interfacial microstructures and achieving high-strength Ti/Al joints, but also offers an effective solution for joining dissimilar metals with large property mismatches.

为了满足轻量化结构的需求，对钛/铝异种焊接构件的需求日益增长。然而，传统的搅拌摩擦搭接技术由于严重的刀具磨损和有限的接头强度而不能满足Ti/Al连接的要求。在本研究中，采用基于涡流的搅拌摩擦搭接（VFSLW）工艺，通过原位形成纳米级非晶间层来减轻刀具磨损并实现高强度Ti/Al结合。系统地研究了焊接参数和刀具配置对接头性能的影响。通过力学测试、微观结构表征和理论分析来阐明基本的键合机制。通过焊接试验，建立了可行的工艺窗口。结果表明，长度为1.8 ~ 2.2 mm的空心搅拌销适用于厚度为3 mm的5083Al板与Ti-6Al-4V板的VFSLW。在转速为100 rpm，焊接速度为15 mm/min，空心搅拌销长度为2.2 mm时，获得了最佳接头，最大线载荷为484 N/mm。在Ti/Al界面上观察到纳米级非晶层，这对实现优异的接头性能起着至关重要的作用。该非晶层的形成主要是由于较弱的物质流动和较低的反应温度。本研究不仅为控制界面微观结构和实现高强度Ti/Al接头建立了理论框架，而且为连接性能不匹配较大的异种金属提供了有效的解决方案。

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引用次数: 0

Achieving high strength-ductility of the selective laser melted Al-Cu-Mg alloy via in-situ sub-micron TiB2 addition and process parameter optimization 通过亚微米级TiB2的原位添加和工艺参数的优化，实现了选择性激光熔化Al-Cu-Mg合金的高强度延展性

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-10 DOI: 10.1016/j.jmatprotec.2026.119246

Songhao Liu , Mao Feng , Longbo Zhang , Chong Tian , Yanjin Xu , Wei Wang , Guo Zhang , Chong Chen , Zongning Chen , Kunming Pan , Shizhong Wei

To address the prevalent issues of extreme hot cracking behavior and coarse columnar grain structures dominated by strong textures in precipitation-strengthened Al alloys during selective laser melting (SLM), sub-micron TiB₂ particles (0.1–1 μm) were introduced, yielding a high-strength and crack-free Al-3.4Cu-0.8Mg alloy whose microstructure is primarily composed of fine equiaxed grains with a random orientation distribution. At 1 wt% TiB₂, crack count decreases but average crack size increases significantly, this is likely because grain refinement altered the crack evolution process. When the TiB₂ content increased to 3 wt%, solidification cracks are fully eliminated, and the alloy’s microstructure consists entirely of fine equiaxed grains (∼1.44 μm). Multi-scale microstructural characterization revealed that TiB₂ particles contributed to excellent grain refinement not only via their inherent heterogeneous nucleation ability but also by promoting dendrite fragmentation and exerting a grain boundary pinning effect. Tensile tests showed the as-fabricated alloy exhibited outstanding strength and ductility, with an ultimate tensile strength (UTS) of 426 MPa, fracture elongation (EL) of 13.3 %, these properties superior to most SLM-fabricated aluminum (Al) alloys. Quantitative analysis of strengthening factors indicated that cracks were the primary cause of property degradation (accounting for 62 %–80 % of the loss in ideal yield strength), whereas Hall-Petch strengthening dominates the improvement in alloy properties. This study provides novel insights and approaches for the preparation process, crack evolution and inhibition, grain refinement, and performance optimization of high-strength Al alloys fabricated via SLM.

为了解决沉淀强化铝合金在选择性激光熔化过程中存在的极端热裂行为和以强织构为主的粗柱状晶粒结构的问题，引入亚微米TiB2颗粒（0.1-1 μm），制备了一种高强无裂纹的Al-3.4 cu -0.8 mg合金，其显微组织主要由取向随机分布的细小等轴晶组成。在1 wt% TiB2时，裂纹数减少，但平均裂纹尺寸显著增大，这可能是由于晶粒细化改变了裂纹演化过程。当TiB2含量增加到3 wt%时，凝固裂纹完全消除，合金组织完全由细小的等轴晶（~ 1.44 μm）组成。多尺度显微结构表征表明，TiB2颗粒不仅具有内在的非均相形核能力，还具有促进枝晶断裂和施加晶界钉住效应的作用。拉伸试验表明，该合金具有良好的强度和延展性，极限抗拉强度（UTS）为426 MPa，断裂伸长率（EL）为13.3 %，这些性能优于大多数slm制备的铝合金。强化因素的定量分析表明，裂纹是合金性能退化的主要原因（占理想屈服强度损失的62% % ~ 80% %），而Hall-Petch强化对合金性能的改善起主导作用。本研究为SLM法制备高强铝合金的制备工艺、裂纹演化与抑制、晶粒细化和性能优化提供了新的见解和方法。

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引用次数: 0

Modelling and simulation of solute segregation and eutectic phase precipitation during laser directed energy deposition of precipitation-strengthened Ni-based superalloys 激光定向能沉积析出强化镍基高温合金过程中溶质偏析和共晶相析出的建模与模拟

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-07 DOI: 10.1016/j.jmatprotec.2026.119251

Hao Fang , Gang Dong , Huaping Wu , Honghao Ge , Jianhua Yao , Chinnapat Panwisawas

Non-equilibrium microstructures develop during the rapid solidification in laser directed energy deposition. The inevitable formation of eutectic phases, typically represented by the Laves phase, during the solidification of Ni-based superalloys is generally detrimental to the alloy properties and may even induce cracking. Understanding the precipitation of such eutectic phases in relation to dendritic growth and solute segregation is particularly important for reducing cracking susceptibility and suppressing crack initiation. A multi-scale model was employed to simulate melt pool dynamics, dendrite growth, solute segregation, and eutectic phase precipitation during laser directed energy deposition of technological precipitation-strengthened Ni-based superalloys under varying energy inputs, considering low to high segregation alloys. The model accurately captures macro-scale melt pool flow heat transfer and micro-scale competitive dendrite growth, validated against experimental melt pool dimensions, primary dendrite arm spacing (PDAS), and eutectic phase morphology. More significantly, the alloy-specific undercooling parameter quantitatively governs the microstructural response across various Ni-based superalloys: higher values of alloy-specific undercooling parameter enhance heterogeneous nucleation, columnar-to-equiaxed transition, and eutectic formation, whereas lower values favour columnar dominance and refined microstructures. These collective insights establish critical process-alloy-microstructure linkages essential for controlling cracking susceptibility.

激光定向能沉积快速凝固过程中会产生非平衡组织。镍基高温合金在凝固过程中不可避免地形成以Laves相为代表的共晶相，这对合金的性能是不利的，甚至可能导致开裂。了解这些共晶相的析出与枝晶生长和溶质偏析的关系，对于降低裂纹敏感性和抑制裂纹起裂尤为重要。采用多尺度模型模拟了不同能量输入条件下工艺析出强化镍基高温合金在激光定向能沉积过程中的熔池动力学、枝晶生长、溶质偏析和共晶相析出。该模型准确捕捉了宏观尺度的熔池流动传热和微观尺度的竞争性枝晶生长，并通过实验熔池尺寸、初生枝晶臂间距（PDAS）和共晶相形态进行了验证。更重要的是，合金特定过冷参数定量地控制了各种ni基高温合金的显微组织响应：较高的合金特定过冷参数增强了非均相成核、柱状向等轴转变和共晶的形成，而较低的合金特定过冷参数有利于柱状优势和细化的显微组织。这些共同的见解建立了控制裂纹敏感性的关键工艺-合金-微观结构联系。

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引用次数: 0

Pulsed laser machining of silicon carbide wafers: A review 碳化硅晶圆的脉冲激光加工研究进展

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-05 DOI: 10.1016/j.jmatprotec.2026.119241

Yu Xuehua , Wei Haiying , Zhang Yi , Qing Zelong , Liu Fu , Yang Yuchao , Li Yanpu

Achieving low-damage, high-quality, and high-efficiency pulsed laser processing of silicon carbide (SiC) wafers remains a significant challenge. During the machining of wide-bandgap SiC wafers, defects such as laser-induced thermal damage, stress-induced cracks, and non-thermal phase transitions are generated during the laser energy deposition process, ultimately leading to processing quality that falls short of expectations. The primary difficulty lies in controlling heat, stress, and crack propagation to minimize the machining damage of wafers. This paper systematically examines the interaction mechanisms between lasers and SiC wafers, presenting a comparative analysis of the single- and multi-pulse process mechanisms of nanosecond and ultrafast lasers in surface ablation process. The pulsed laser damage mechanisms of SiC wafers differ between the surface and bulk. A critical review of existing studies highlights their limitations. Focusing on process damage caused by lasers with different pulse widths, we investigate various machining techniques, including laser drilling, grooving, dicing, and slicing, and explore the impact of pulsed laser ablation and stealth processing on machining quality. Optimization strategies are summarized, and emerging trends in current research are discussed. Finally, we provide an outlook on the future development of pulsed laser processing for SiC wafers, offering insights into its industrial application.

实现低损伤、高质量和高效率的脉冲激光加工碳化硅（SiC）晶圆仍然是一个重大挑战。在宽禁带SiC晶圆加工过程中，激光能量沉积过程中会产生激光致热损伤、应力致裂纹、非热相变等缺陷，最终导致加工质量达不到预期。主要的难点在于控制热、应力和裂纹扩展，以使晶圆的加工损伤最小化。本文系统地研究了激光与SiC晶圆的相互作用机制，对比分析了纳秒激光和超快激光在表面烧蚀过程中的单脉冲和多脉冲过程机制。脉冲激光损伤SiC晶圆的机理在表面和本体上存在差异。对现有研究的批判性回顾突出了它们的局限性。针对不同脉冲宽度激光造成的加工损伤，研究了激光打孔、开槽、切割、切片等加工技术，并探讨了脉冲激光烧蚀和隐身加工对加工质量的影响。总结了优化策略，并讨论了当前研究的新趋势。最后，我们对脉冲激光加工SiC晶圆的未来发展进行了展望，并对其工业应用提出了见解。

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引用次数: 0

Stable coaxial hot-wire laser metal wire deposition of high-performance invar alloy through critical melting state control and thermal feedback regulation 通过临界熔化状态控制和热反馈调节实现高性能invar合金同轴热线激光金属丝的稳定沉积

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-02 DOI: 10.1016/j.jmatprotec.2026.119244

Zhenwen Zhu, Yu Shi, Yufen Gu, Youwei Xu, Ziyou Ren, Yang Zhai

Coaxial Hot-Wire Laser Metal Wire Deposition offers distinct advantages for fabricating large-scale, thin-walled Invar alloy components in thermally sensitive aerospace applications. However, inherent thermal accumulation during the additive process typically triggers process instability, precluding the realization of continuous, uninterrupted manufacturing. To address these challenges, this study first identifies the optimal laser focal position at the substrate surface (0 mm) as a prerequisite for a stable liquid-bridge transition. By integrating high-speed imaging with infrared thermography, the "critical melting state" of the wire is precisely defined, and a mathematical model correlating wire feed speed with laser power is established to ensure precise energy coupling. To overcome the fundamental bottleneck of thermal buildup during continuous deposition, a novel active control strategy based on "constant laser power with hot-wire current feedback regulation" is developed. This mechanism dynamically compensates for heat fluctuations to maintain a sustained energy balance, thereby enabling highly stable and uninterrupted additive manufacturing. The deposited structures exhibited a dense, defect-free austenitic matrix with fine spherical or ellipsoidal NbC precipitates along grain boundaries and interdendritic regions. Due to grain refinement and Orowan precipitation strengthening, the alloy achieved excellent mechanical performance, with a horizontal tensile strength of 652 MPa—among the highest reported for additively manufactured Invar alloys. Simultaneously, it maintains a commercial-grade minimum coefficient of thermal expansion (CTE) of 1.93 × 10⁻⁶ K⁻¹. This research confirms the feasibility of Coaxial Hot-Wire Laser Metal Wire Deposition for high-performance Invar alloys and elucidates the intrinsic process-microstructure-property relationships, providing a robust theoretical and technological foundation for the high-precision continuous manufacturing of Invar structures.

同轴热丝激光金属丝沉积为热敏航空航天应用中制造大型薄壁因瓦尔合金部件提供了明显的优势。然而，在增材过程中固有的热积累通常会引发过程不稳定，从而阻碍了连续、不间断制造的实现。为了解决这些挑战，本研究首先确定了衬底表面的最佳激光焦点位置（0 mm），作为稳定液桥过渡的先决条件。通过将高速成像与红外热成像相结合，精确定义了金属丝的“临界熔化状态”，并建立了金属丝进给速度与激光功率之间的数学模型，保证了能量的精确耦合。为了克服连续沉积过程中热积累的根本瓶颈，提出了一种基于“恒定激光功率-热线电流反馈调节”的新型主动控制策略。该机制动态补偿热波动，以维持持续的能量平衡，从而实现高度稳定和不间断的增材制造。沉积组织为致密的无缺陷奥氏体基体，沿晶界和枝晶间有细小的球形或椭球状NbC析出。由于晶粒细化和Orowan沉淀强化，该合金获得了优异的力学性能，水平抗拉强度为652 mpa，是增材制造Invar合金中最高的。同时，它保持了商业级的最小热膨胀系数（CTE） 1.93 × 10⁻⁶K⁻¹。本研究证实了同轴热丝激光金属丝沉积技术用于高性能Invar合金的可行性，阐明了其内在的工艺-显微组织-性能关系，为高精度连续制造Invar结构提供了坚实的理论和技术基础。

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引用次数: 0