Journal of Materials Processing Technology最新文献_第10页

Suppressing thin-wall instability through self-pressurizing of the medium: A novel gas-liquid low-pressure tube forming technology 通过介质自加压抑制薄壁不稳定性：一种新型气液低压管成形技术

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-10-26 DOI: 10.1016/j.jmatprotec.2025.119120

Hang Yuan , Gaoning Tian , Yanli Lin , Yi Xu , Zhijie Hu , Kelin Chen , Zhubin He

A novel gas-liquid hybrid low-pressure forming (GLLF) process is proposed, which employs a compressible gas-liquid medium with a tunable compression ratio to eliminate pressure fluctuations and produce an optimal pressure profile for plastic deformation, thereby effectively suppressing compression instability. We develop a gas-liquid hybrid medium compression model based on Soave-Redlich-Kwong (SRK) real-gas equation and solubility theory, quantifying the roles of initial gas fraction, initial pressure, and volume compression ratio on pressure evolution. Experimental validation yields a maximum prediction error of only 2.17 %. A critical support pressure curve for thin-walled tubes at different compression ratios was experimentally measured to characterize wrinkling instability. A strategy for effectively suppressing wrinkling by adjusting the gas-liquid ratio and initial pressure was proposed. Experiments on 6061-O aluminum tubes (round, flat, and rectangular cross-sections) reveal that the material flow behavior under GLLF, with thickening primarily concentrated in the sidewalls and fillet regions—reaching up to twice the average circumferential compression. Finally, deployment of a GLLF production system enabled the manufacturing of e-bike tubular components with a significant improvement in efficiency, underscoring its potential for sustainable and high-efficiency production. Beyond practical benefits, this work establishes fundamental advances in pressure–volume coupling laws, critical pressure criteria, and deformation-flow mechanisms, offering a transferable framework for process design across diverse tubular geometries and materials.

提出了一种新型的气液混合低压成形（GLLF）工艺，采用压缩比可调的可压缩气液介质消除压力波动，产生塑性变形的最佳压力分布，从而有效抑制压缩不稳定性。基于Soave-Redlich-Kwong （SRK）实气方程和溶解度理论，建立了气液混合介质压缩模型，量化了初始气体分数、初始压力和体积压缩比对压力演化的影响。实验验证的最大预测误差仅为2.17 %。实验测量了薄壁管在不同压缩比下的临界支撑压力曲线，以表征起皱失稳。提出了一种通过调节气液比和初始压力来有效抑制起皱的策略。对6061-O铝管（圆形、扁平和矩形截面）的实验表明，在GLLF作用下，材料的流动行为主要集中在侧壁和圆角区域，其增厚程度可达平均周向压缩的两倍。最后，GLLF生产系统的部署使电动自行车管状部件的生产效率得到了显著提高，突显了其可持续和高效生产的潜力。除了实际效益之外，这项工作还在压力-体积耦合定律、临界压力标准和变形-流动机制方面取得了根本性的进展，为不同管状结构和材料的工艺设计提供了可转移的框架。

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引用次数: 0

Corrigendum to “Effect of pouring temperature on distribution characteristics and formation mechanism of eutectic-rich band in vacuum-assisted high pressure die casting AlSi9MnMg alloy” [J. Mater. Process. Tech. 345 (2025) 119066] 浇注温度对真空辅助高压压铸AlSi9MnMg合金富共晶带分布特征及形成机制的影响[J]。板牙。的过程。Tech. 345 (2025) 119066]

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-10-25 DOI: 10.1016/j.jmatprotec.2025.119099

Ganlin Qin , Jian Lin , Xiao Liu , Hanlin Xiang , Congchang Xu , Luoxing Li

引用次数: 0

Thin-film metallization and micro-assembly driven comparative failure modes in advanced ceramic packaging under thermal cycling 热循环下先进陶瓷封装中薄膜金属化和微组装驱动的比较失效模式

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-10-24 DOI: 10.1016/j.jmatprotec.2025.119119

Jinhong Liu , Song Wu , Taotao Chen , Junfu Liu , Shuye Zhang , Peng He

AlN and Al₂O₃ ceramic substrates are increasingly adopted in high-performance electronic packaging owing to their excellent thermal conductivity, electrical insulation, and mechanical strength—features that are crucial for heterogeneous integration systems. However, compare with the extensively studied FR4-based structures, the reliability degradation of ceramic-based solder joints under thermal cycling, particularly the processing–structure–failure relationship, remains insufficiently understood. In this work, AlN- and Al₂O₃-based flip-chip assemblies were fabricated through thin-film metallization, micro-ball bumping, thermocompression bonding, and underfill dispensing. The thermal fatigue behavior of SAC305 solder joints was systematically investigated through combined experimental characterization and finite element simulation. After 1000 thermal cycles, distinct cracking patterns emerged: AlN-based joints exhibited cracks at both upper ((Pt, Au)-Sn IMC/solder) and lower ((Cu, Ni, Au)₆Sn₅ IMC/solder) interfaces, whereas Al₂O₃-based joints fractured only at the upper interface. Finite element analysis revealed that underfill effectively mitigated in-plane (xy) shear stresses but failed to suppress out-of-plane (z-axis) tensile stresses, which dominated crack initiation and propagation. Crack formation was more severe in the AlN system due to higher mismatch-induced stress and greater strain energy accumulation, leading to earlier crack onset and faster propagation. All cracks developed via microvoid nucleation and coalescence. Cs-corrected STEM further clarified the interfacial IMC structures and elemental site occupancies, showing that Ni preferentially occupied Cu2 lattice sites, whereas Au substituted Cu1 sites in (Cu, Ni, Au)₆Sn₅. These findings elucidate how processing-induced interfacial architecture and substrate-dependent stress evolution jointly govern the reliability of ceramic-based solder joints, providing guidance for designing next-generation high-power electronic packaging.

AlN和Al2O3陶瓷衬底越来越多地用于高性能电子封装，因为它们具有优异的导热性，电绝缘性和机械强度-这些特性对异质集成系统至关重要。然而，与广泛研究的fr4基焊点结构相比，陶瓷基焊点在热循环下的可靠性退化，特别是工艺-结构-失效关系，仍然没有得到充分的了解。在这项工作中，通过薄膜金属化，微球碰撞，热压键合和下填充点胶制备了基于AlN和al2o3的倒装芯片组件。采用实验表征与有限元模拟相结合的方法，系统研究了SAC305焊点的热疲劳行为。经过1000次热循环后，出现了明显的裂纹模式：al2o3基接头在上部（Pt, Au)-Sn IMC/钎料)和下部（Cu, Ni, Au）6Sn5 IMC/钎料）界面均出现裂纹，而al2o3基接头仅在上部界面断裂。有限元分析表明，下填土可以有效抑制面内（xy）剪应力，但不能抑制面外(z)拉应力，而面外(z)拉应力主导着裂纹的萌生和扩展。在AlN体系中，由于失配引起的应力更高，应变能积累更大，裂纹形成更严重，导致裂纹发生时间更早，扩展速度更快。所有裂纹均通过微孔洞成核和聚并形成。cs校正的STEM进一步澄清了界面IMC结构和元素位占比，表明（Cu, Ni, Au）6Sn5中Ni优先占据Cu2晶格位，而Au取代Cu1晶格位。这些发现阐明了加工诱导的界面结构和衬底相关应力演变如何共同控制陶瓷基焊点的可靠性，为设计下一代大功率电子封装提供指导。

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引用次数: 0

Improving surface quality of LDED thin-wall Ti-6Al-4V alloy with ultralow influence on superficial layer via femtosecond laser polishing 利用飞秒激光抛光技术提高了对表层超低影响的led薄壁Ti-6Al-4V合金表面质量

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-10-24 DOI: 10.1016/j.jmatprotec.2025.119121

Li Zhang , Wentai Ouyang , Shuowen Zhang , Xiaoxiao Chen , Chunhai Guo , Rujia Wang , Xiaoming Duan , Xiaodong Yang , Wenwu Zhang , Liyuan Sheng

Laser direct energy deposited (LDED) Ti-6Al-4V thin-wall components enables the lightweight development of low altitude vehicle but suffers from poor surface quality. Whereas, the specific characteristics of both material and structure limit the polishing effect of mechanical methods and the common laser polishing methods, e.g. nanosecond laser polishing (NLP), considering the structural deformation and superficial microstructure evolution. Hence, a preferable polishing method could be vital for applying such component, and the corresponding influences on overall structure and superficial microstructure need thorough investigation. In the present research, the femtosecond laser polishing (FLP) was used to improve the surface quality of LDED Ti-6Al-4V thin-wall plate, meanwhile decreasing the thermal influence, and the effects were compared to the NLP with corresponding parameters. The results reveal that FLP could decrease the surface roughness from 37.24 μm to 4.97 μm by selectively removing the peak region of melting track. Meanwhile, the depths of oxide layer and heat affected zone (HAZ) were limited within 400 nm and 5 μm, respectively, even in the air environment, and no obvious structural deformation could be observed. In contrast, NLP could result in dense cracks on surface and poorer surface quality due to the severe oxidation behavior and rapid solidification, accompanying with the formation of thick oxide layer and deep HAZ in superficial layer, and the great structural deformation could be caused. Moreover, the further wearing test confirmed the minor influence of FLP on surface layer. This work establishes FLP as a viable method for the high-precision polishing on thin-wall Ti-6Al-4V alloy in air environment, overcoming the limitations of conventional techniques for critical components.

激光直接能量沉积（LDED） Ti-6Al-4V薄壁组件实现了低空车辆的轻量化发展，但其表面质量较差。然而，材料和结构的特殊特性限制了机械方法和普通激光抛光方法（如纳秒激光抛光（NLP））的抛光效果，考虑了结构变形和表面微观组织演变。因此，选择一种合适的抛光方法对该组件的应用至关重要，并且需要深入研究其对整体结构和表面显微组织的影响。本研究采用飞秒激光抛光技术（FLP）改善了Ti-6Al-4V薄壁led板的表面质量，同时减小了热影响，并与具有相应参数的NLP效果进行了比较。结果表明：FLP选择性去除熔迹峰区，可使表面粗糙度从37.24 μm降低到4.97 μm；同时，即使在空气环境中，氧化层深度和热影响区（HAZ）也被限制在400 nm和5 μm以内，未观察到明显的结构变形。而NLP由于氧化行为严重，凝固速度快，表面裂纹密集，表面质量较差，表面氧化层较厚，表层热影响区较深，造成较大的组织变形。进一步的磨损试验证实了FLP对表面层的影响较小。本研究为Ti-6Al-4V薄壁合金在空气环境下的高精度抛光建立了一种可行的FLP方法，克服了传统技术对关键部件的局限性。

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引用次数: 0

Mitigating microstructural and mechanical heterogeneity in WAAM-fabricated Ni-Cr-Mo-based superalloy via post-heat treatment 通过后热处理改善waam制备的ni - cr - mo基高温合金的组织和力学不均匀性

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-10-24 DOI: 10.1016/j.jmatprotec.2025.119115

Hongxi Jin , Jinwei Long , Yingjie Kong , Jiacheng Chu , Meng Wang , Xuan Liu , Wenyong Zhao , Fangfang Liu , Yanfa Han , Yanhong Wei

Ni-Cr-Mo-based superalloys are well-suited for fabricating components for high-temperature acidic environments via wire arc additive manufacturing (WAAM) due to their corrosion resistance and low hot-cracking susceptibility. Layer-by-layer deposition and non-equilibrium solidification can cause repeated thermal cycling and element segregation, leading to heterogeneous microstructures that significantly affect mechanical properties. In this study, Hastelloy C-276 thin-walled components were fabricated by gas tungsten arc welding (GTAW)-based WAAM to investigate the effects of thermal cycling on microstructure and mechanical properties, as well as the potential of post-heat treatments to eliminate microstructural and mechanical heterogeneity. The as-built samples exhibited columnar grains along the build direction and interdendritic P-phase enriched in Mo. Thermal cycling promoted the formation of M₆C carbides and reduced primary dendrite arm spacing, leading to gradient mechanical properties, with ultimate tensile strength (UTS) increasing from 491.2 MPa (top) to 615.9 MPa (bottom). To mitigate this gradient, solution heat treatment (SHT) and SHT followed by aging (SHT+AHT) were applied. SHT effectively dissolved precipitates, induced recrystallization, refined grains, and formed coincidence site lattice boundaries, thereby homogenizing the microstructure and mechanical properties with an increase of the average UTS by 12.5 %. In contrast, SHT+AHT led to extensive precipitation of M₆C and μ phases along grain boundaries, which significantly reduced ductility, with elongation decreasing by 22.1 %. Besides, thermodynamic simulations were used to reveal the formation mechanism of P-phase, μ phase, and M₆C carbides. This work elucidated the correlation between temperature, thermodynamics, microstructure, and mechanical properties, providing valuable guidance for achieving uniform mechanical properties in WAAM-fabricated components.

由于ni -cr - mo基高温合金具有耐腐蚀性和低热裂敏感性，因此非常适合通过电弧增材制造（WAAM）制造高温酸性环境中的部件。逐层沉积和非平衡凝固会导致反复的热循环和元素偏析，导致不均匀的显微组织，从而显著影响力学性能。在本研究中，采用基于气体钨极电弧焊（GTAW）的WAAM工艺制备了哈氏合金C-276薄壁构件，研究了热循环对其组织和力学性能的影响，以及热处理后消除组织和力学不均匀性的潜力。热循环促进了M6C碳化物的形成，减小了初生枝晶臂间距，形成了梯度力学性能，其极限抗拉强度（UTS）从491.2 MPa（上）增加到615.9 MPa（下）。为了缓解这种梯度，采用固溶热处理（SHT）和SHT后时效（SHT+AHT）。SHT有效溶解析出相，诱导再结晶，细化晶粒，形成重合点位晶格边界，使组织和力学性能均质化，平均UTS提高12. %。相反，SHT+AHT导致沿晶界广泛析出M6C和μ相，显著降低了延展性，伸长率降低了22.1% %。通过热力学模拟揭示了p相、μ相和M6C碳化物的形成机理。本研究阐明了温度、热力学、微观结构与力学性能之间的关系，为实现waam材料的均匀力学性能提供了有价值的指导。

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引用次数: 0

Deterministic texturing of blazed nano-gratings with fully controlled 3D topography via oblique vibration-assisted diamond cutting 斜向振动辅助金刚石切割的完全控制三维形貌的燃烧纳米光栅的确定性纹理

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-10-24 DOI: 10.1016/j.jmatprotec.2025.119123

Changcheng Lin, Qinghou Cheng, Yingxue Yao, Yang Yang

Blazed nano-gratings are critical functional components in a series of optoelectronic devices, such as diffractive waveguide AR displays and high-performance spectrometers, due to their high diffraction efficiency. Their optical performance depends critically on precise 3D topography, making fabrication technology a key focus in academic and industrial research. However, deterministic texturing of blazed gratings with high-precision and fully controlled 3D topographies on various metallic materials remains challenging. This paper proposes an oblique triangle vibration-assisted diamond cutting (OTVDC) process for the deterministic texturing of blazed nano-gratings with fully controlled 3D topographies. A bidirectional mapping framework linking process parameters to grating topography is established through kinematic analysis, providing the theoretical basis for deterministic topography control and process parameter selection. Furthermore, by comprehensively analyzing the experimentally measured tool trajectory, three-directional dynamic cutting forces, and chip morphology, the formation mechanism of blazed nano-gratings is systematically revealed. The material adaptability of the proposed process is demonstrated by successfully machining blazed nano-gratings with uniform and controlled 3D topography on aluminum alloy, brass, 304 stainless steel, and nickel-plated stainless steel, with minimal tool wear. In addition to deterministic texturing of blazed nano-gratings on various metallic materials, this work also advances fundamental understanding of oblique cutting processes and lays the foundation for generating other micro/nano structures with fully controlled 3D topography.

燃烧纳米光栅由于具有较高的衍射效率，是衍射波导AR显示器、高性能光谱仪等一系列光电子器件的关键功能部件。它们的光学性能在很大程度上取决于精确的3D形貌，这使得制造技术成为学术和工业研究的关键焦点。然而，在各种金属材料上确定具有高精度和完全控制的三维地形的燃烧光栅纹理仍然具有挑战性。本文提出了一种斜三角形振动辅助金刚石切割（OTVDC）工艺，用于具有完全控制的三维形貌的燃烧纳米光栅的确定性纹理。通过运动学分析，建立了工艺参数与光栅地形的双向映射框架，为确定性地形控制和工艺参数选择提供了理论依据。通过对实验测量的刀具轨迹、三向动态切削力和切屑形貌的综合分析，系统揭示了燃烧纳米光栅的形成机理。通过在铝合金、黄铜、304不锈钢和镀镍不锈钢上成功加工具有均匀和可控三维形貌的火焰纳米光栅，证明了该工艺对材料的适应性，并且刀具磨损最小。除了确定各种金属材料上的燃烧纳米光栅的纹理外，这项工作还促进了对斜切割过程的基本理解，并为产生具有完全控制的三维形貌的其他微/纳米结构奠定了基础。

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引用次数: 0

Impact of ultrasonic rolling micro-texture shape on anodic oxidation nanotube growth and wear resistance in micro-nano textured titanium alloy implants 超声轧制微织构形状对微纳织构钛合金植入体阳极氧化纳米管生长及耐磨性的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-10-23 DOI: 10.1016/j.jmatprotec.2025.119122

Teng Li , Ying Meng , Xiuli Fu , Yingwen Li , Qiaomu Han , Zhenfeng Jiang

Implants exposed to fretting corrosion release wear debris, causing inflammation, bone loss, and loosening. In this study, we employed ultrasonic rolling technology to construct linear and arc-shaped microtextures on the surface of Ti-6Al-4V, combined with an anodized TiO₂ nanotube layer, which can improve the wear resistance of orthopedic implants. We applied anodization using micron-scale ultrasonic rolling microtextures as the base to grow nano-scale nanotubes on the surface, thereby creating micro/nano multiscale textures to enhance the tribological performance of the titanium alloy implants. We analyzed the influence of the texture shape on the nanotube growth, the strengthening mechanism, and tribological effects. Additionally, we characterized the surface morphology, hardness, and phase composition. The results indicate that the texture shape significantly regulates nanotube growth and friction performance. When compared with the linear textures, the curvature of the arc textures forms secondary peaks/valleys, which increases the reaction area. Combined with the edge "tip effect," this promotes oxygen enrichment, thereby yielding thicker, highly crystalline nanotubes on the arcs. Tribologically, arc textures disperse stress and enhance debris entrapment, thereby significantly inhibiting the three-body wear. The wear scar depth reduced by 74.3 % versus the polished substrate. The wear volume of the counterpart ball against the arc texture (224,174 μm³) was only 43.5 % of that against the linear texture. The micro-nano synergy further reduced the wear volume of the arc composite (197,510 μm³) by 66.7 % when compared with the single nanotube layer. In this study, we proposed the optimization of the texture shape combined with anodic oxidation to enhance the Ti alloy implant tribology, which supports reliable biomedical bone implant application.

植入物暴露在微动腐蚀下会释放磨损碎片，引起炎症、骨质流失和松动。在本研究中，我们采用超声轧制技术在Ti-6Al-4V表面构建线性和弧形微织构，并结合阳极氧化的TiO₂纳米管层，可以提高骨科植入物的耐磨性。我们采用微米级超声轧制微织构阳极氧化为基础，在表面生长纳米级纳米管，从而形成微纳多尺度织构，以提高钛合金植入体的摩擦学性能。分析了织构形状对纳米管生长、强化机理和摩擦学效应的影响。此外，我们表征了表面形貌，硬度和相组成。结果表明，织构形状对纳米管的生长和摩擦性能有显著的调节作用。与线性织构相比，弧形织构的曲率形成二次峰/谷，增加了反应面积。结合边缘的“尖端效应”，这促进了氧的富集，从而在弧线上产生更厚、高度结晶的纳米管。在摩擦学上，圆弧织构分散应力，增强碎屑夹持，从而显著抑制三体磨损。与抛光后的基材相比，磨损痕深度降低了74.3 %。弧织构对球的磨损量（224174 μm³）仅为直线织构对球磨损量的43.5 %。与单纳米管层相比，微纳协同作用进一步降低了电弧复合材料（197,510 μ³）的磨损体积66.7 %。在本研究中，我们提出了优化织构形状并结合阳极氧化来增强钛合金种植体的摩擦学性能，从而支持可靠的生物医学骨种植体应用。

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引用次数: 0

Strategy composition regulation and strength-ductility enhancement of TA15 titanium alloy/high-entropy alloy gradient structure fabricated by laser direct energy deposition 激光直接能量沉积制备TA15钛合金/高熵合金梯度结构的策略、成分调控及强塑性增强

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-10-22 DOI: 10.1016/j.jmatprotec.2025.119116

Leilei Wang, Linqin Li, Longxiang Sun, Jiahao Zhang, Yanze Wang, Xiaohong Zhan

The AlNbTiVZr high-entropy alloy exhibits exceptionally high-temperature specific strength, positioning it as a highly promising candidate for hot-section components exposed to intense heat flux and mechanical loading. The integrated design requirements for thermal protection and load bearing necessitate dependable bonding between the high-entropy alloy and the matrix. However, discrepancies in composition and thermo-physical properties between these materials often result in defects and strength degradation. In this investigation, a reliable metallurgical bonding was established between the TA15 titanium alloy and the AlNbTiVZr high-entropy alloy through strategic composition design of the transition region, followed by successful laser direct energy deposition with power regulation and subsequent post-treatment. By examining the microstructural evolution of the TA15/AlNbTiVZr gradient materials and integrating the results with thermal-fluid coupling simulations, the impact of temperature gradient and growth rate on microstructural evolution during the laser direct energy deposition process was systematically explored. The complex changes in grain morphology were attributed to the dynamic variations in the temperature gradient of the melting pool, differences in thermal conductivity, and the effects of diffusion coefficient disparities between the materials. The optimized transition region exhibited an ultimate tensile strength of 1038 MPa with an elongation of 8.1 %. This study not only enhances the comprehension of microstructural evolution in gradient materials but also presents a promising approach for developing high-performance materials with tailored properties.

AlNbTiVZr高熵合金具有极高的高温比强度，使其成为暴露在强热流和机械载荷下的热截面部件的非常有前途的候选材料。热防护和承载的综合设计要求要求高熵合金与基体之间的可靠结合。然而，这些材料在组成和热物理性能上的差异经常导致缺陷和强度下降。在本研究中，通过对过渡区的战略性成分设计，在TA15钛合金和AlNbTiVZr高熵合金之间建立了可靠的冶金结合，随后进行了功率调节的激光直接能量沉积和后续的后处理。通过对TA15/AlNbTiVZr梯度材料微观组织演变的研究，并结合热流体耦合模拟，系统探讨了激光直接能量沉积过程中温度梯度和生长速率对微观组织演变的影响。熔池温度梯度的动态变化、热导率的差异以及材料间扩散系数差异的影响导致了晶粒形貌的复杂变化。优化后的过渡区抗拉强度为1038 MPa，延伸率为8.1 %。该研究不仅提高了对梯度材料微观结构演变的理解，而且为开发具有定制性能的高性能材料提供了一条有希望的途径。

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引用次数: 0

Melt pool height monitoring based on dynamic laser spot in Oscillating Laser Arc Hybrid Additive Manufacturing 基于动态激光光斑的振荡激光电弧混合增材制造熔池高度监测

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-10-22 DOI: 10.1016/j.jmatprotec.2025.119117

Zheng Meng , Chengyuan Ma , Shenghong Yan , Yuxuan Zhang , Bo Chen , Caiwang Tan , Xiaoguo Song

Oscillating Laser Arc Hybrid Additive Manufacturing (OLAH-AM) combines the deposition efficiency of arc with the energy-manipulation capability of an oscillating laser, making it suitable for fabricating large-scale metal components. A key challenge in achieving automation and repeatability in OLAH-AM is the lack of robust technologies capable of reliably monitoring melt pool height. The fundamental advancement of this study is a novel melt pool height measurement method that requires only a single co-planar camera. The innovation lies in using the laser spot that is inherently generated by the oscillating laser-arc hybrid heat source on the melt pool as the sensing target, enabling stable and rapid extraction of height information. The core of this method lies in accurately localizing the laser spot under complex melt pool interference. To this end, an improved object detection model was developed by incorporating a P2 feature layer and a weighted bidirectional feature pyramid network (BiFPN), which achieved a recall rate of 85.5 % and mAP of 93.3 %. The subsequent height fitting was accomplished by employing the Random Sample Consensus (RANSAC) algorithm for parabolic fitting and applying perspective transformation to the curve's peak point. The proposed method achieved a height measurement error of 3.75 %, with each measurement requiring only 41.37 ms. Validation experiments confirmed the effectiveness of this approach, which lays a crucial foundation for future real-time stability control in robotic OLAH-AM processes.

振荡激光电弧混合增材制造（OLAH-AM）将电弧的沉积效率与振荡激光的能量操纵能力相结合，使其适用于制造大型金属部件。在OLAH-AM中实现自动化和可重复性的一个关键挑战是缺乏能够可靠地监测熔池高度的可靠技术。本研究的基本进展是一种新的熔池高度测量方法，只需要一个共面相机。创新之处在于利用熔池上振荡激光-电弧混合热源固有的激光光斑作为传感目标，能够稳定快速地提取高度信息。该方法的核心是在复杂熔池干扰下精确定位激光光斑。为此，结合P2特征层和加权双向特征金字塔网络（BiFPN），开发了改进的目标检测模型，召回率为85.5 %，mAP为93.3 %。随后的高度拟合采用抛物线拟合的随机样本一致性（RANSAC）算法，并对曲线的峰值点进行透视变换。该方法的高度测量误差为3.75 %，每次测量仅需41.37 ms。验证实验验证了该方法的有效性，为未来机器人OLAH-AM过程的实时稳定性控制奠定了重要基础。

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引用次数: 0

Surface modifications and prominent high-temperature vibration fatigue resistance of nickel-based thin-walled blade simulators via synchronous double-sided ultrasonic rolling 同步双面超声轧制镍基薄壁叶片模拟器表面改性及优异的高温振动疲劳抗力

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-10-22 DOI: 10.1016/j.jmatprotec.2025.119118

Huayi Cheng , Kaiming Zhang , Lin Zhu , Shulei Yao , Lei Kang , Ji Wang , Wei Peng , Chengcheng Zhang , Shuang Liu , Xiancheng Zhang , Shantung Tu

The ultrasonic surface rolling process (USRP) has emerged as a promising technique for the anti-fatigue manufacturing of aero-engine blades. However, blades operate under harsh conditions—sustained vibration loads and high temperatures—casting doubt on the long-term efficacy of this surface strengthening method. Given the thin-walled and low-stiffness structural characteristics of blade components, there is an urgent need for a process that balances strengthening effects with machining-induced deformation. To address this gap, this study developed a novel synchronous double-sided ultrasonic rolling process (SDSURP), designed to simultaneously achieve surface strengthening and suppress machining deformation. Experiments were conducted on nickel-based blade simulators—ultra-thin structures with the thinnest section ∼0.3 mm—tailored to closely mimic the structural characteristics of real aero-engine blades. High-temperature (650 °C) vibration fatigue test results demonstrated that the high-cycle fatigue strength at 3 × 10⁷ cycles was significantly improved, manifesting a 15.5 % increase over untreated specimens. This enhancement in fatigue performance can be primarily attributed to positive effects induced by SDSURP: the formation of a refined surface microstructure, the introduction of compressive residual stress, and the long-term stability of these two key features under harsh service conditions. Unlike studies that only evaluate surface treatment effectiveness at the material level, this research focuses on developing process implementation methods tailored to the specific structural characteristics of blades. The proposed double-sided strengthening strategy thus provides practical technical guidance for applying surface strengthening techniques to thin-walled components in the aerospace field.

超声表面滚压工艺（USRP）已成为航空发动机叶片抗疲劳制造的一种很有前途的技术。然而，叶片在恶劣的条件下工作——持续的振动载荷和高温——使人怀疑这种表面强化方法的长期有效性。考虑到叶片部件薄壁和低刚度的结构特点，迫切需要一种平衡强化效果和加工变形的工艺。为了解决这一问题，本研究开发了一种新型的同步双面超声轧制工艺（SDSURP），旨在同时实现表面强化和抑制加工变形。在镍基叶片模拟器上进行了实验-最薄截面为~ 0.3 mm的超薄结构，量身定制以接近模拟真实航空发动机叶片的结构特征。高温（650℃）振动疲劳试验结果表明，在3 × 107次循环下，高周疲劳强度显著提高，比未处理的试样提高15.5 %。这种疲劳性能的增强主要归因于SDSURP的积极作用：形成精致的表面微观结构，引入压残余应力，以及在恶劣使用条件下这两个关键特征的长期稳定性。与仅在材料层面评估表面处理效果的研究不同，本研究侧重于开发针对叶片特定结构特征的工艺实施方法。所提出的双面强化策略为航空航天领域薄壁件表面强化技术的应用提供了实用的技术指导。

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