Pub Date : 2025-03-05DOI: 10.1016/j.jmatprotec.2025.118793
Tianyu Xu , Xiuquan Ma , Chaoqun Wu , Jinliang Zhang , Wenchao Ke , Minghui Yang
Laser welding of aluminum alloys is prone to porosity formation, which significantly compromises joint strength. In this study, the successful incorporation of carbon nanotubes(CNTs) into aluminum alloy welds not only increased welding speed but also enhanced joint strength while maintaining comparable weld penetration depth. The key point is that the comprehensive impact of CNTs on the joint has been systematically studied. Differential scanning calorimetry(DSC) and phase diagram analysis revealed that the exothermic reaction between CNTs and the aluminum matrix promoted the formation of Al₄C₃. Mechanical properties analysis demonstrated that the maximum tensile strength of the CNTs reinforced joint reached 326 MPa, outperforming most laser welding processes. On a microstructural level, CNTs refined the grain size of the weld fusion zone by 35.5 %, facilitating dynamic recrystallization and resulting in anisotropic grain structures. Microtexture analysis showed that some CNTs were dispersed within the weld, providing a stress transfer pathway at the CNTs/aluminum interface. This work comprehensively reveals the enhancement effect of carbon nanotubes on joints, and provides new potential solutions for optimizing the welding process of power battery casings.
{"title":"Comprehensive regulation of carbon nanotubes on laser welded joints of aluminum alloy: From morphology, solidification, microtexture to properties","authors":"Tianyu Xu , Xiuquan Ma , Chaoqun Wu , Jinliang Zhang , Wenchao Ke , Minghui Yang","doi":"10.1016/j.jmatprotec.2025.118793","DOIUrl":"10.1016/j.jmatprotec.2025.118793","url":null,"abstract":"<div><div>Laser welding of aluminum alloys is prone to porosity formation, which significantly compromises joint strength. In this study, the successful incorporation of carbon nanotubes(CNTs) into aluminum alloy welds not only increased welding speed but also enhanced joint strength while maintaining comparable weld penetration depth. The key point is that the comprehensive impact of CNTs on the joint has been systematically studied. Differential scanning calorimetry(DSC) and phase diagram analysis revealed that the exothermic reaction between CNTs and the aluminum matrix promoted the formation of Al₄C₃. Mechanical properties analysis demonstrated that the maximum tensile strength of the CNTs reinforced joint reached 326 MPa, outperforming most laser welding processes. On a microstructural level, CNTs refined the grain size of the weld fusion zone by 35.5 %, facilitating dynamic recrystallization and resulting in anisotropic grain structures. Microtexture analysis showed that some CNTs were dispersed within the weld, providing a stress transfer pathway at the CNTs/aluminum interface. This work comprehensively reveals the enhancement effect of carbon nanotubes on joints, and provides new potential solutions for optimizing the welding process of power battery casings.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118793"},"PeriodicalIF":6.7,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143563055","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}
The importance of temperature for the quality of laser shock peening has been recognized in recent years. Heat accumulation caused by the overall heating mode adopted by the existing method will inevitably cause changes in the microstructure of the unreinforced region, which in turn will affect the mechanical properties of the overall structure. In this paper, a localized high-temperature laser shock peening with adjustable metallic coatings (Loc-HLSPwC) was proposed for the low-cost, large-scale, and highly flexible fabrication of fatigue-enhanced structural components. The experimental results showed that compared with the samples fabricated by high-temperature laser shock without coatings, the strengthened regions of Loc-HLSPwC samples exhibited significant hardness and larger peak residual compressive stresses, and the Loc-HLSPwC samples exhibited more excellent fatigue performance. The adjustable metallic coatings changed the direction of microcrack expansion during the loading process of fatigue loading. The microstructure and hardness of the unstrengthened regions of Loc-HLSPwC samples did not change significantly. Loc-HLSPwC process is expected to provide a new idea for high reliability manufacturing of new generation of construction machinery equipment.
{"title":"Localized high-temperature laser shock peening with adjustable metallic coatings method for mechanical properties enhancement of reflective aluminum alloys","authors":"Xiaohan Zhang , Qingyun Zhu , Mingyi Zheng , Yaowu Hu","doi":"10.1016/j.jmatprotec.2025.118792","DOIUrl":"10.1016/j.jmatprotec.2025.118792","url":null,"abstract":"<div><div>The importance of temperature for the quality of laser shock peening has been recognized in recent years. Heat accumulation caused by the overall heating mode adopted by the existing method will inevitably cause changes in the microstructure of the unreinforced region, which in turn will affect the mechanical properties of the overall structure. In this paper, a localized high-temperature laser shock peening with adjustable metallic coatings (Loc-HLSPwC) was proposed for the low-cost, large-scale, and highly flexible fabrication of fatigue-enhanced structural components. The experimental results showed that compared with the samples fabricated by high-temperature laser shock without coatings, the strengthened regions of Loc-HLSPwC samples exhibited significant hardness and larger peak residual compressive stresses, and the Loc-HLSPwC samples exhibited more excellent fatigue performance. The adjustable metallic coatings changed the direction of microcrack expansion during the loading process of fatigue loading. The microstructure and hardness of the unstrengthened regions of Loc-HLSPwC samples did not change significantly. Loc-HLSPwC process is expected to provide a new idea for high reliability manufacturing of new generation of construction machinery equipment.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118792"},"PeriodicalIF":6.7,"publicationDate":"2025-03-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143563056","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}
Fabricating nanostructures on metallic surface is relevant to various applications, and there is growing interest in developing new methods that balance accuracy, throughput and cost. In this work, a novel method, underwater electrical wire explosion shock imprinting (UEWESI), is proposed as a versatile one-step method for imprinting large-area surface nanostructures on both thin and thick substrates. Using a polycarbonate mold, the 10 μm thickness and 40 × 40 mm² area aluminium foil was uniformly imprinted via single copper wire explosion at a 12 mm standoff distance and 1.8 kJ electrical stored energy, with a fidelity up to 80 %. A periodic imprinting mechanism based on the stress evolution in the substrate was proposed to explore the physical process and explain the effects of standoff distance, shock wave pulse width, substrate thickness and layer arrangement on imprinting performance. Additionally, a scaled-up variant of UEWESI utilizing an exploding wire array was introduced, which generates a large-area planar shock wave front through the convergence of individual shock waves, further enhancing imprinting performance. This work offers a promising alternative for large-scale fabrication of nanostructures on metallic surfaces, with potential applications in flexible electronics, rechargeable batteries, plasmonics and other related fields.
{"title":"Imprinting nanostructures on metallic surface via underwater electrical wire explosion shock waves","authors":"Xin Li, Huantong Shi, Tuan Li, Zhigang Liu, Jian Wu, Xingwen Li","doi":"10.1016/j.jmatprotec.2025.118784","DOIUrl":"10.1016/j.jmatprotec.2025.118784","url":null,"abstract":"<div><div>Fabricating nanostructures on metallic surface is relevant to various applications, and there is growing interest in developing new methods that balance accuracy, throughput and cost. In this work, a novel method, underwater electrical wire explosion shock imprinting (UEWESI), is proposed as a versatile one-step method for imprinting large-area surface nanostructures on both thin and thick substrates. Using a polycarbonate mold, the 10 μm thickness and 40 × 40 mm² area aluminium foil was uniformly imprinted via single copper wire explosion at a 12 mm standoff distance and 1.8 kJ electrical stored energy, with a fidelity up to 80 %. A periodic imprinting mechanism based on the stress evolution in the substrate was proposed to explore the physical process and explain the effects of standoff distance, shock wave pulse width, substrate thickness and layer arrangement on imprinting performance. Additionally, a scaled-up variant of UEWESI utilizing an exploding wire array was introduced, which generates a large-area planar shock wave front through the convergence of individual shock waves, further enhancing imprinting performance. This work offers a promising alternative for large-scale fabrication of nanostructures on metallic surfaces, with potential applications in flexible electronics, rechargeable batteries, plasmonics and other related fields.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118784"},"PeriodicalIF":6.7,"publicationDate":"2025-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143549344","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}
Pub Date : 2025-02-28DOI: 10.1016/j.jmatprotec.2025.118791
Jinsheng Ji , Leilei Wang , Jianfeng Wang , Yuchi Fang , Zhangping Hu , Qiyu Gao , Deliang Lei , Xiaohong Zhan
Wire-arc directed energy deposition (DED-Arc) combined with interlayer plastic strengthening has shown good advantages and feasibility in manufacturing high-performance components. However, simultaneously improving strength and ductility remains challenging. Based on DED-Arc technology, this study proposed a hybrid manufacturing approach integrating interlayer hammering and in-situ heating. The impacts of the novel process on pore inhibition, microstructure evolution, and mechanical properties were explored. The results indicated that, compared to the conventionally deposited alloy, the alloy produced via the novel process demonstrates increases of 28.3 % in yield strength, 22.2 % in ultimate tensile strength, and 21.8 % in ductility. The simultaneous improvement of alloy strength and ductility arose from the combined effects of the thermal and mechanical forces, primarily through pore inhibition, grain refinement, precipitation strengthening, and increased dislocation density. This study overcame the strength-ductility trade-off, providing new insights for improving techniques to enhance the performance of DED-Arc components.
{"title":"Enhanced strength-ductility of deposited Al-Mg-Sc alloy through interlayer hammering and in-situ heating","authors":"Jinsheng Ji , Leilei Wang , Jianfeng Wang , Yuchi Fang , Zhangping Hu , Qiyu Gao , Deliang Lei , Xiaohong Zhan","doi":"10.1016/j.jmatprotec.2025.118791","DOIUrl":"10.1016/j.jmatprotec.2025.118791","url":null,"abstract":"<div><div>Wire-arc directed energy deposition (DED-Arc) combined with interlayer plastic strengthening has shown good advantages and feasibility in manufacturing high-performance components. However, simultaneously improving strength and ductility remains challenging. Based on DED-Arc technology, this study proposed a hybrid manufacturing approach integrating interlayer hammering and in-situ heating. The impacts of the novel process on pore inhibition, microstructure evolution, and mechanical properties were explored. The results indicated that, compared to the conventionally deposited alloy, the alloy produced via the novel process demonstrates increases of 28.3 % in yield strength, 22.2 % in ultimate tensile strength, and 21.8 % in ductility. The simultaneous improvement of alloy strength and ductility arose from the combined effects of the thermal and mechanical forces, primarily through pore inhibition, grain refinement, precipitation strengthening, and increased dislocation density. This study overcame the strength-ductility trade-off, providing new insights for improving techniques to enhance the performance of DED-Arc components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118791"},"PeriodicalIF":6.7,"publicationDate":"2025-02-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143549345","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}
Pub Date : 2025-02-26DOI: 10.1016/j.jmatprotec.2025.118790
Zimin Tang , Yongshan Lu , Feng Ding , Lijuan Zheng , Chengyong Wang
This study aims to fabricate Zr-based metallic glass (MG) parts directly through friction stir joining (FSJ) by addressing the poor machinability of Zr-based MGs. The joining mechanism, mechanical properties, and microstructure of FSJ joints were investigated to achieve high-strength joints. The result identified uneven temperature distribution at the joint interface as a critical factor for inadequate plastic deformation or viscous flow, affecting the joint strength. Therefore, a new strategy is proposed to regulate the interface temperature and material plastic deformation during Zr-based MG joining via ultrafast laser micro-texturing of the joining surface combined with ultrasonic vibration-assisted friction stir joining (UL-UVaFSJ). The results show that ultrasonic vibrations enhance longitudinal friction and energy transfer, promoting uniform temperature distribution with improved viscous flow. Additionally, ultrafast laser-fabricated micro-textures alter heat generation, reducing temperature unevenness at the source. These factors collectively yield a uniform temperature distribution at the joint interface, crucial for reliable joining. The factors also maintain the even plastic flow of Zr-based MGs in the supercooled liquid region (SCLR) for a critical duration, essential for successful joining. Transmission electron microscopy reveals true metallurgical joining with the proposed method. The joining strength of Zr-based MGs is 1.37 GPa, reaching 91.3 % of the as-cast material and enabling the successful fabrication of a high-strength, crystallization-free MG gear shaft. The findings are pivotal for large-scale MG part fabrication and will significantly promote their industrial application.
{"title":"Ultrafast laser micro-texturing of joining surface combined with ultrasonic vibration-assisted friction stir joining to fabricate Zr-based metallic glass parts","authors":"Zimin Tang , Yongshan Lu , Feng Ding , Lijuan Zheng , Chengyong Wang","doi":"10.1016/j.jmatprotec.2025.118790","DOIUrl":"10.1016/j.jmatprotec.2025.118790","url":null,"abstract":"<div><div>This study aims to fabricate Zr-based metallic glass (MG) parts directly through friction stir joining (FSJ) by addressing the poor machinability of Zr-based MGs. The joining mechanism, mechanical properties, and microstructure of FSJ joints were investigated to achieve high-strength joints. The result identified uneven temperature distribution at the joint interface as a critical factor for inadequate plastic deformation or viscous flow, affecting the joint strength. Therefore, a new strategy is proposed to regulate the interface temperature and material plastic deformation during Zr-based MG joining via ultrafast laser micro-texturing of the joining surface combined with ultrasonic vibration-assisted friction stir joining (UL-UVaFSJ). The results show that ultrasonic vibrations enhance longitudinal friction and energy transfer, promoting uniform temperature distribution with improved viscous flow. Additionally, ultrafast laser-fabricated micro-textures alter heat generation, reducing temperature unevenness at the source. These factors collectively yield a uniform temperature distribution at the joint interface, crucial for reliable joining. The factors also maintain the even plastic flow of Zr-based MGs in the supercooled liquid region (SCLR) for a critical duration, essential for successful joining. Transmission electron microscopy reveals true metallurgical joining with the proposed method. The joining strength of Zr-based MGs is 1.37 GPa, reaching 91.3 % of the as-cast material and enabling the successful fabrication of a high-strength, crystallization-free MG gear shaft. The findings are pivotal for large-scale MG part fabrication and will significantly promote their industrial application.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118790"},"PeriodicalIF":6.7,"publicationDate":"2025-02-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143520594","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}
Pub Date : 2025-02-26DOI: 10.1016/j.jmatprotec.2025.118782
Mehdi Rouhani , Sai Bhavani Sravan Metla , Jonathan Hobley , Dileep Karnam , Chia-Hung Hung , Yu-Lung Lo , Yeau-Ren Jeng
Laser cutting of silicon carbide (SiC) poses significant challenges due to its extreme hardness and thermal resistance, necessitating high energy input and often leading to extensive melt-zone formation and collateral damage. This study optimizes nanosecond laser cutting of SiC by systematically investigating phase transformations, melt-zone formation, and debris deposition, offering a cost-effective alternative to femtosecond laser systems. Using Raman spectroscopy, photoluminescence, and X-ray photoelectron spectroscopy, we construct a comprehensive phase distribution map of the laser-affected region, revealing key material transformations. Our results demonstrate that material removal is confined to a narrow central fissure. Meanwhile, the surrounding melt zone consists of phase-separated amorphous silicon (a-Si) and amorphous carbon (a-C). Lateral crevasses mark the interface between the melt zone and the unmodified SiC substrate. We further explore the influence of atmospheric conditions (oxygen, air, and argon) and laser pulse parameters (pulse width and repetition rate) on melt-zone formation and cutting efficiency. Oxygen-rich environments expand the melt zone and yield oxygen-rich debris, while inert atmospheres suppress oxidation, forming carbon-rich debris with less material loss. Shorter pulse widths enhance material removal while reducing melt-zone expansion, supporting a mechanistic framework in which sequential multiphoton absorption drives ablation while photothermal effects govern melt-zone formation. This study provides critical insights into optimizing nanosecond laser cutting of SiC, offering practical strategies for achieving high-precision cuts with less thermal damage and material waste. These findings contribute to advancing industrial laser machining of SiC, making high-precision, low-cost processing more accessible and efficient.
{"title":"A complete phase distribution map of the laser affected zone and ablation debris formed by nanosecond laser-cutting of SiC","authors":"Mehdi Rouhani , Sai Bhavani Sravan Metla , Jonathan Hobley , Dileep Karnam , Chia-Hung Hung , Yu-Lung Lo , Yeau-Ren Jeng","doi":"10.1016/j.jmatprotec.2025.118782","DOIUrl":"10.1016/j.jmatprotec.2025.118782","url":null,"abstract":"<div><div>Laser cutting of silicon carbide (SiC) poses significant challenges due to its extreme hardness and thermal resistance, necessitating high energy input and often leading to extensive melt-zone formation and collateral damage. This study optimizes nanosecond laser cutting of SiC by systematically investigating phase transformations, melt-zone formation, and debris deposition, offering a cost-effective alternative to femtosecond laser systems. Using Raman spectroscopy, photoluminescence, and X-ray photoelectron spectroscopy, we construct a comprehensive phase distribution map of the laser-affected region, revealing key material transformations. Our results demonstrate that material removal is confined to a narrow central fissure. Meanwhile, the surrounding melt zone consists of phase-separated amorphous silicon (a-Si) and amorphous carbon (a-C). Lateral crevasses mark the interface between the melt zone and the unmodified SiC substrate. We further explore the influence of atmospheric conditions (oxygen, air, and argon) and laser pulse parameters (pulse width and repetition rate) on melt-zone formation and cutting efficiency. Oxygen-rich environments expand the melt zone and yield oxygen-rich debris, while inert atmospheres suppress oxidation, forming carbon-rich debris with less material loss. Shorter pulse widths enhance material removal while reducing melt-zone expansion, supporting a mechanistic framework in which sequential multiphoton absorption drives ablation while photothermal effects govern melt-zone formation. This study provides critical insights into optimizing nanosecond laser cutting of SiC, offering practical strategies for achieving high-precision cuts with less thermal damage and material waste. These findings contribute to advancing industrial laser machining of SiC, making high-precision, low-cost processing more accessible and efficient.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118782"},"PeriodicalIF":6.7,"publicationDate":"2025-02-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143527053","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}
Pub Date : 2025-02-24DOI: 10.1016/j.jmatprotec.2025.118789
Guoxing Su, Yu Shi, Ming Zhu, Gang Zhang
Enhancing the wire deposition rate while ensuring deposition stability is a critical challenge in fabricating large nickel-based alloy components using hot wire laser directed energy deposition (HW-LDED) technology. In this study, a preheating mathematical model for Inconel 718 wire was initially established and experimentally validated. Subsequently, based on the optimal matching between the wire feeding speed and preheating current, Inconel 718 components were efficiently fabricated with a wire deposition rate of 3.1 kg/h. Ultimately, the microstructure evolution, phase composition, and mechanical properties of the HW-LDED Inconel 718 samples were comprehensively investigated. The results revealed that the microstructure of the HW-LDED Inconel 718 samples consisted of columnar dendrites exhibiting a pronounced {100} < 001 > texture, with an average grain size of 16 μm. The primary phase in the HW-LDED Inconel 718 samples was the γ-Ni phase, accompanied by Laves and carbides in intergranular regions. The average hardness of the HW-LDED Inconel 718 samples was 253.5 HV1.0. The tensile strength and elongation were 1112.1 MPa and 36.13 %, respectively, while the impact absorbing energy reached 85.97 J. The tensile and impact fracture surfaces displayed numerous dimples, indicative of ductile fracture behavior of the alloy under applied loading. The Laves phase facilitated the initiation and propagation of cracks during the alloy's deformation process, with elongated Laves phases undergoing fragmentation and smaller Laves phases experiencing debonding from the matrix. This research presents a viable solution for the efficient fabrication of large nickel-based alloy components. Furthermore, the findings offer valuable insights into the interrelationships among the deposition process, microstructure, and properties of the HW-LDED Inconel 718 alloy.
{"title":"Application of hot wire laser directed energy deposition for efficient fabrication of large nickel-based alloy components: Process, microstructure, and mechanical properties","authors":"Guoxing Su, Yu Shi, Ming Zhu, Gang Zhang","doi":"10.1016/j.jmatprotec.2025.118789","DOIUrl":"10.1016/j.jmatprotec.2025.118789","url":null,"abstract":"<div><div>Enhancing the wire deposition rate while ensuring deposition stability is a critical challenge in fabricating large nickel-based alloy components using hot wire laser directed energy deposition (HW-LDED) technology. In this study, a preheating mathematical model for Inconel 718 wire was initially established and experimentally validated. Subsequently, based on the optimal matching between the wire feeding speed and preheating current, Inconel 718 components were efficiently fabricated with a wire deposition rate of 3.1 kg/h. Ultimately, the microstructure evolution, phase composition, and mechanical properties of the HW-LDED Inconel 718 samples were comprehensively investigated. The results revealed that the microstructure of the HW-LDED Inconel 718 samples consisted of columnar dendrites exhibiting a pronounced {100} < 001 > texture, with an average grain size of 16 μm. The primary phase in the HW-LDED Inconel 718 samples was the γ-Ni phase, accompanied by Laves and carbides in intergranular regions. The average hardness of the HW-LDED Inconel 718 samples was 253.5 HV1.0. The tensile strength and elongation were 1112.1 MPa and 36.13 %, respectively, while the impact absorbing energy reached 85.97 J. The tensile and impact fracture surfaces displayed numerous dimples, indicative of ductile fracture behavior of the alloy under applied loading. The Laves phase facilitated the initiation and propagation of cracks during the alloy's deformation process, with elongated Laves phases undergoing fragmentation and smaller Laves phases experiencing debonding from the matrix. This research presents a viable solution for the efficient fabrication of large nickel-based alloy components. Furthermore, the findings offer valuable insights into the interrelationships among the deposition process, microstructure, and properties of the HW-LDED Inconel 718 alloy.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118789"},"PeriodicalIF":6.7,"publicationDate":"2025-02-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143520593","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}
Pub Date : 2025-02-24DOI: 10.1016/j.jmatprotec.2025.118788
Xuefeng Tang , Chuanyue He , Xinyun Wang , Feifei Hu , Lei Deng , Jianxin Xie , M.W. Fu
Online monitoring of defect evolution during metal forming is crucial for achieving closed-loop control of product quality. The incorporation of reinforcement phases in metal matrix composites (MMCs) results in changes to micro-defect evolution and damage modes, thereby rendering the online monitoring of defect evolution more complex and challenging. Here, the authors proposed a novel intelligent sensing approach that can not only detect the formation of micro-defect but also identify the damage mode during plastic deformation of MMCs. By leveraging anomaly detection with an autoencoder to analyze the power spectral density (PSD) of acoustic emission (AE) signals collected during plastic deformation, the signals from the TC4 matrix and TiB reinforcement in a discontinuously reinforced titanium matrix composite (DRTMC) can be distinguished. Based on the intelligent sensing framework, it was found for the first time that the evolution of the TiB signals PSD correlates with defect evolution, and TiB fractures occur during the early to mid-stages of plastic deformation. It further utilizes autoencoders in conjunction with unsupervised clustering to associate the AE signals from TiB with two distinct damage modes: fracture of TiB whiskers and microcrack penetrating the matrix. The effects of stress state on the formation of defect and damage mode were also recognized by the developed approach. The effects of TiB content and stress state on the grain-level deformation behavior and damage evolution mechanism during plastic deformation of DRTMC were analyzed by full-field crystal plasticity simulation with uncoupled damage model. A TiB content of 3 % in TiB/TC4 enhances matrix slip and improves plastic deformation capability. However, under shear deformation, TiB's load-bearing contribution is minimal. High stress triaxiality from a notch causes TiB-induced cracks to penetrate the matrix at lower strains, leading to failure. This study provides a promising method for the online monitoring of defect evolution during the plastic forming and service processes of MMCs.
{"title":"A novel online sensing approach for monitoring micro-defect and damage mode during the plastic deformation of metal matrix composites: Experiment and crystal plasticity analysis","authors":"Xuefeng Tang , Chuanyue He , Xinyun Wang , Feifei Hu , Lei Deng , Jianxin Xie , M.W. Fu","doi":"10.1016/j.jmatprotec.2025.118788","DOIUrl":"10.1016/j.jmatprotec.2025.118788","url":null,"abstract":"<div><div>Online monitoring of defect evolution during metal forming is crucial for achieving closed-loop control of product quality. The incorporation of reinforcement phases in metal matrix composites (MMCs) results in changes to micro-defect evolution and damage modes, thereby rendering the online monitoring of defect evolution more complex and challenging. Here, the authors proposed a novel intelligent sensing approach that can not only detect the formation of micro-defect but also identify the damage mode during plastic deformation of MMCs. By leveraging anomaly detection with an autoencoder to analyze the power spectral density (PSD) of acoustic emission (AE) signals collected during plastic deformation, the signals from the TC4 matrix and TiB reinforcement in a discontinuously reinforced titanium matrix composite (DRTMC) can be distinguished. Based on the intelligent sensing framework, it was found for the first time that the evolution of the TiB signals PSD correlates with defect evolution, and TiB fractures occur during the early to mid-stages of plastic deformation. It further utilizes autoencoders in conjunction with unsupervised clustering to associate the AE signals from TiB with two distinct damage modes: fracture of TiB whiskers and microcrack penetrating the matrix. The effects of stress state on the formation of defect and damage mode were also recognized by the developed approach. The effects of TiB content and stress state on the grain-level deformation behavior and damage evolution mechanism during plastic deformation of DRTMC were analyzed by full-field crystal plasticity simulation with uncoupled damage model. A TiB content of 3 % in TiB/TC4 enhances matrix slip and improves plastic deformation capability. However, under shear deformation, TiB's load-bearing contribution is minimal. High stress triaxiality from a notch causes TiB-induced cracks to penetrate the matrix at lower strains, leading to failure. This study provides a promising method for the online monitoring of defect evolution during the plastic forming and service processes of MMCs.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118788"},"PeriodicalIF":6.7,"publicationDate":"2025-02-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143512379","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}
Pub Date : 2025-02-22DOI: 10.1016/j.jmatprotec.2025.118775
Kaiming Zhang , Ji Wang , Huayi Cheng , Shulei Yao , Changli Liu , Chengcheng Zhang , Xueran Yu , Shuang Liu , Xiancheng Zhang , Shantung Tu
To enhance the vibration fatigue resistance of thin-walled components, surface strengthening techniques have gained significant attention in the aerospace industry. This study introduces the synchronous double-sided ultrasonic surface rolling process (SDUSRP) as a promising method for improving the fatigue resistance of thin-walled components. Experiments were conducted on specially designed specimens simulating the structure of aero-engine blade edges. Two different SDUSRP parameters, primarily differing in the ultrasonic amplitude, were applied to create distinct surface strengthening effects on the specimens. Compared to untreated specimens, those treated with SDUSRP exhibited a fatigue life extension of approximately 10–100 times in different fatigue loads. The substantial improvement in fatigue performance is attributed to the stable fine-grain layer, high amplitude compressive residual stress and their cyclic stability. Additionally, higher ultrasonic amplitude enhances grain refinement through dislocation proliferation and the formation of dislocation slip bands, leading to the fragmentation and separation of grains. The SDUSRP technique demonstrated in this study shows great potential for tailoring and adjusting residual stress and microstructure in thin-walled structures, offering a valuable complement to existing anti-fatigue manufacturing methods for such components.
{"title":"Improving fatigue performance of thin-walled components via synchronous double-sided ultrasonic surface rolling process","authors":"Kaiming Zhang , Ji Wang , Huayi Cheng , Shulei Yao , Changli Liu , Chengcheng Zhang , Xueran Yu , Shuang Liu , Xiancheng Zhang , Shantung Tu","doi":"10.1016/j.jmatprotec.2025.118775","DOIUrl":"10.1016/j.jmatprotec.2025.118775","url":null,"abstract":"<div><div>To enhance the vibration fatigue resistance of thin-walled components, surface strengthening techniques have gained significant attention in the aerospace industry. This study introduces the synchronous double-sided ultrasonic surface rolling process (SDUSRP) as a promising method for improving the fatigue resistance of thin-walled components. Experiments were conducted on specially designed specimens simulating the structure of aero-engine blade edges. Two different SDUSRP parameters, primarily differing in the ultrasonic amplitude, were applied to create distinct surface strengthening effects on the specimens. Compared to untreated specimens, those treated with SDUSRP exhibited a fatigue life extension of approximately 10–100 times in different fatigue loads. The substantial improvement in fatigue performance is attributed to the stable fine-grain layer, high amplitude compressive residual stress and their cyclic stability. Additionally, higher ultrasonic amplitude enhances grain refinement through dislocation proliferation and the formation of dislocation slip bands, leading to the fragmentation and separation of grains. The SDUSRP technique demonstrated in this study shows great potential for tailoring and adjusting residual stress and microstructure in thin-walled structures, offering a valuable complement to existing anti-fatigue manufacturing methods for such components.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118775"},"PeriodicalIF":6.7,"publicationDate":"2025-02-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143508384","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}
Pub Date : 2025-02-22DOI: 10.1016/j.jmatprotec.2025.118787
Renhao Wu , Zaigham Saeed Toor , Man Jae SaGong , Yue Wu , Xinmei Liu , Meng Li , Hyoung Seop Kim
Laminated aluminum alloy-steel (Al-St) sheets exhibit significant potential for use in industrial applications because of their superior mechanical and physical properties. Differences in the intrinsic mechanical properties of these different laminates cause challenges in fabrication and plastic forming. Thermally assisted mechanical joining and forming methods exhibit significant limitations in regulating the formation of Fe-Al intermetallic compounds within Al-St laminates. Cracks can easily occur at the bonding interfaces of these laminates, which severely limits their application. Therefore, a novel forming process is necessary. This study introduces an integrated friction stir-assisted double-sided incremental forming process with synchronous bonding (FS-DSIF&SB) that combines bonding and deformation to fabricate truncated laminated conical components using dissimilar AA5052 and DC05 sheets. A modified fracture criterion, incorporating stress triaxiality, temperature, and strain rate, is developed and implemented using a VUSDFLD subroutine to evaluate ductile damage under diverse thermo-mechanical conditions. Experimental validation using high-temperature tensile tests and forming trials confirm the predictive accuracy of the fracture model. Damage progression reveals that the outer aluminum alloy layer experiences higher damage, leading to fracture. Optimized processing enhanced laminate's formability and variable wall angle compatibility. The findings underscore the process's high formability and demonstrate its potential applicability for multi-material systems and advanced manufacturing scenarios.
{"title":"Investigation on formability and fracture mechanisms of dissimilar DC05/AA5052 sheets in an integrated friction stir-assisted double-sided incremental synchronous forming-bonding process","authors":"Renhao Wu , Zaigham Saeed Toor , Man Jae SaGong , Yue Wu , Xinmei Liu , Meng Li , Hyoung Seop Kim","doi":"10.1016/j.jmatprotec.2025.118787","DOIUrl":"10.1016/j.jmatprotec.2025.118787","url":null,"abstract":"<div><div>Laminated aluminum alloy-steel (Al-St) sheets exhibit significant potential for use in industrial applications because of their superior mechanical and physical properties. Differences in the intrinsic mechanical properties of these different laminates cause challenges in fabrication and plastic forming. Thermally assisted mechanical joining and forming methods exhibit significant limitations in regulating the formation of Fe-Al intermetallic compounds within Al-St laminates. Cracks can easily occur at the bonding interfaces of these laminates, which severely limits their application. Therefore, a novel forming process is necessary. This study introduces an integrated friction stir-assisted double-sided incremental forming process with synchronous bonding (FS-DSIF&SB) that combines bonding and deformation to fabricate truncated laminated conical components using dissimilar AA5052 and DC05 sheets. A modified fracture criterion, incorporating stress triaxiality, temperature, and strain rate, is developed and implemented using a VUSDFLD subroutine to evaluate ductile damage under diverse thermo-mechanical conditions. Experimental validation using high-temperature tensile tests and forming trials confirm the predictive accuracy of the fracture model. Damage progression reveals that the outer aluminum alloy layer experiences higher damage, leading to fracture. Optimized processing enhanced laminate's formability and variable wall angle compatibility. The findings underscore the process's high formability and demonstrate its potential applicability for multi-material systems and advanced manufacturing scenarios.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"338 ","pages":"Article 118787"},"PeriodicalIF":6.7,"publicationDate":"2025-02-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143480203","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}
扫码关注我们
求助内容：
应助结果提醒方式：
京公网安备 11010802042870号