Journal of Materials Processing Technology最新文献_第2页

Reducing stripping force in ultrasonic-assisted exfoliation of laser-modified 4H-SiC wafers 激光修饰4H-SiC晶圆超声辅助剥离过程中剥离力的减小

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-20 DOI: 10.1016/j.jmatprotec.2026.119226

Hongmei Li , Hongwei Wang , Yuxin Li , Wenyang Cen , Liqun Wang , Lin Li , Yinzhou Yan , Kewen Pan , Wei Guo

High-efficiency, low-damage exfoliation of 4H-SiC wafers is critical for their application in the power electronics sector and for reducing manufacturing costs. However, the high exfoliation force required after conventional laser modification is a core challenge for this technology. This study systematically reveals two primary physical causes for the high exfoliation force. First, the laser induces a complex modified layer, comprising an amorphous phase and 3C-SiC, resulting in strong interfacial bonding with the 4H-SiC substrate. Second, the crystal’s inherent ∼4° off-axis growth mode results in a stepped and staggered crack distribution during propagation, which prevents the cracks from becoming fully interconnected. To address these issues, an innovative hybrid exfoliation technique is proposed and validated. The proposed technique combines ultrasonic cavitation with selective chemical etching using a KOH solution. Ultrasonic vibration and cavitation physically drive microcrack propagation, while selective chemical etching weakens the interfacial bonding strength of the modified layer. This synergistic method reduces the exfoliation force to 26.85 N (representing a reduction of 66.01 %). Building on this, we further optimize the laser modification process by designing a dual-modification strategy that introduces interconnection points to proactively control the crack path and ensure complete crack-network connectivity. Ultimately, this fully optimized strategy reduces the exfoliation force to 19.85 N and achieves efficient exfoliation of a complete 6-inch 4H-SiC wafer in approximately 3 min. This study elucidates the specific origins of the high exfoliation force through microstructural and elemental analysis of the modified layer and provides a new feasible and scalable solution for low-damage wafer exfoliation.

高效、低损伤的4H-SiC晶圆剥离对于其在电力电子领域的应用和降低制造成本至关重要。然而，常规激光修饰后所需的高剥离力是该技术的核心挑战。本研究系统地揭示了高剥离力的两个主要物理原因。首先，激光诱导出由非晶相和3C-SiC组成的复杂修饰层，从而与4H-SiC衬底形成强界面键合。其次，晶体固有的~ 4°离轴生长模式导致裂纹在扩展过程中呈阶梯状和交错分布，这阻止了裂纹完全互连。为了解决这些问题，提出并验证了一种创新的混合去角质技术。提出的技术结合超声空化和选择性化学蚀刻使用KOH溶液。超声振动和空化物理驱动微裂纹扩展，而选择性化学腐蚀削弱了改性层的界面结合强度。这种协同方法将剥离力降低到26.85 N（降低66.01 %）。在此基础上，我们进一步优化了激光修饰工艺，设计了引入互连点的双修饰策略，主动控制裂纹路径，确保裂纹网络完全连通性。最终，这种完全优化的策略将剥离力降低到19.85 N，并在大约3 min内实现完整的6英寸4H-SiC晶圆的有效剥离。本研究通过对改性层的微观结构和元素分析，阐明了高剥离力的具体来源，为低损伤硅片剥离提供了一种新的可行的、可扩展的解决方案。

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引用次数: 0

Synergistic mechanism of beam oscillation and Zr micro-alloying: Achieving grain refinement and defect suppression in laser-arc hybrid welding of aluminum alloys 光束振荡与Zr微合金化的协同机制：实现铝合金激光电弧复合焊接的晶粒细化和缺陷抑制

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-19 DOI: 10.1016/j.jmatprotec.2026.119224

Yuhui Xie , Yunfei Meng , Zhichong Li , Yahui Wu , Chao Ge , Yan Liu , Zongtao Zhu , Hui Chen

Weld porosity and joint softening pose significant challenges in laser-arc hybrid welding of thick aluminum alloys. While process optimization and microalloying are known independent remedies, their synergistic coupling mechanism under the non-equilibrium, flow-intensive conditions of laser-arc hybrid welding remains unexplored. This study fundamentally advances the field by revealing how high-frequency beam oscillation interacts with Zr micro-alloying to govern grain refinement and defect suppression. During three-layer laser-arc hybrid welding of 15-mm-thick 6082-T6 alloy, the combined use of laser oscillation and Zr micro-alloying reduced porosity from 8.5 % to near zero and refined the weld grain size by 86.6 % (cap), 93.4 % (filler), and 68.6 % (root). This led to a 30.9 % increase in ultimate tensile strength (to 237 MPa) and a 170 % improvement in elongation, consistently shifting fracture to the heat-affected zone. Mechanistically, the study reveals that oscillation-induced flow fields promote the formation and distribution of both D0₂₃-Al₃Zr phases and submicron Zr particle clusters. The combined application of TEM analysis and the “edge-to-edge” model indicates that submicron Zr possesses a superior grain-refining efficacy over D0₂₃-Al₃Zr due to a stronger crystallographic orientation relationship with the α-Al matrix. This work thus establishes a process-metallurgy synergy framework, demonstrating that controlled melt-pool dynamics can actively activate and harness microalloying elements to tailor non-equilibrium solidification structures, a principle applicable beyond the specific alloy studied.

焊缝气孔和接头软化是厚铝合金激光-电弧复合焊接的一大难题。虽然工艺优化和微合金化是已知的独立补救措施，但它们在非平衡、流动密集的激光-电弧复合焊接条件下的协同耦合机制尚不清楚。该研究通过揭示高频光束振荡如何与Zr微合金化相互作用来控制晶粒细化和缺陷抑制，从根本上推动了该领域的发展。在15mm厚6082-T6合金的三层激光电弧复合焊接过程中，激光振荡和Zr微合金化的联合使用使气孔率从8.5 %降至接近于零，焊缝晶粒细化率分别为86.6% %（焊帽）、93.4 %（填料）和68.6% %（焊根）。这使得极限抗拉强度提高了30.9% %（达到237 MPa），伸长率提高了170 %，断口持续向热影响区转移。研究表明，振荡诱导的流场促进了D023-Al3Zr相和亚微米Zr颗粒团簇的形成和分布。TEM分析和“边对边”模型的结合表明，由于与α-Al基体的晶体取向关系更强，亚微米Zr比D023-Al3Zr具有更好的晶粒细化效果。因此，这项工作建立了一个过程-冶金协同框架，证明受控熔池动力学可以主动激活和利用微合金元素来定制非平衡凝固结构，这一原则适用于所研究的特定合金。

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引用次数: 0

Role of permanent magnetic stirring on the morphologies of both carbide and γ′ phase in GH4742 superalloy during solidification 永磁搅拌对GH4742高温合金凝固过程中碳化物和γ′相形貌的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-19 DOI: 10.1016/j.jmatprotec.2026.119223

Jiahui Wang, Lei Wang, Xiu Song, Yang Liu

The precipitate characteristic is crucial for determining the mechanical properties of GH4742 superalloy ingots. A permanent magnetic stirring (PMS) was applied during the solidification of GH4742 superalloy, and the role of PMS on the carbide and γ′ morphologies was studied through combination of the experimental investigation and first-principles calculation. The results show that the aspect ratio of MC carbides decreases by 55.0 % as the PMS rotation speed increases from 0 to 300 rpm, and the morphology transforms from long strip to short strip or block. Those are mainly attributed to 59.6 % decreasing of the constitutional undercooling at the solidification front caused by the fast mass transport with PMS. However, the γ′ phases in the interdendritic region are more significantly influenced by PMS than those in the dendritic core. The γ′ size in the interdendritic region increases by 44.6 % with the increasing PMS rotation speed from 0 to 300 rpm; the γ′ number decreases by 51.1 %; the γ′ morphology transforms from near cuboid to cuboid, cuboid with concave faces and octet. The γ′ morphology transition in the interdendritic region is dominated by the increased γ′-γ lattice misfit by 212.5 %, which is mainly ascribed to that more Ti atoms occupy the Al sites in γ′ phase resulted from the enhanced electron transfer between Ti to Ni atoms by PMS. This study not only offers an effective approach to control the main precipitates in GH4742 superalloy ingots, but also throws light on the effect mechanisms of PMS on the carbide and γ′ morphologies.

析出相特征是决定GH4742合金锭力学性能的关键因素。采用永磁搅拌（PMS）对GH4742高温合金进行凝固，并结合实验研究和第一性原理计算，研究了永磁搅拌对GH4742高温合金碳化物和γ′形貌的影响。结果表明：随着PMS转速从0 ~ 300 rpm增加，MC碳化物的长径比降低55.0 %，形貌由长条状变为短条状或块状；这主要是由于PMS的快速质量输运使凝固前沿的本质过冷度降低了59.6% %。然而，枝晶间区γ′相受PMS的影响比枝晶核心区γ′相更显著。当PMS转速从0 ~ 300 rpm增加时，枝晶间区γ′尺寸增大44.6% %；γ′数减少51.1 %；γ′形貌由近长方体转变为长方体、凹长方体和八面体。枝晶间的γ′形貌转变主要是γ′-γ晶格错配增加了212.5 %，这主要是由于PMS增强了Ti原子到Ni原子之间的电子转移，导致更多的Ti原子占据了γ′相的Al位。本研究不仅为控制GH4742高温合金锭中的主要析出物提供了有效的方法，而且还揭示了PMS对碳化物和γ′形貌的影响机制。

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引用次数: 0

Direct preparation of laser-induced doped graphite films on glass surfaces under domain-limiting effect for photonic debonding 在限域效应下在玻璃表面直接制备激光诱导掺杂石墨薄膜用于光子脱粘

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-17 DOI: 10.1016/j.jmatprotec.2026.119214

Wenxue Dai , Fangcheng Wang , Ping He , Huijuan Liu , Chenghao Ma , Qiang Liu , Mingqi Huang , Guoping Zhang , Bingpu Zhou , Rong Sun

Constructing doped carbon-based multifunctional films with stable structures and excellent adhesion on glass substrates represents a core challenge and research focus in contemporary materials processing. Traditional high-temperature fabrication processes often suffer from aging and agglomeration of dopant particles, leading to reduced film structural uniformity and severely limiting their application potential in broad-spectrum light absorption and efficient thermal management. Here, we propose an in situ preparation method for laser-induced doped graphite films (LDGF) based on the domain-limiting effect, enabling the one-step construction of multifunctional release layers on glass surfaces. This approach utilizes the localized transient thermal field and non-equilibrium dynamics induced by ultraviolet lasers to promote the formation of stable interlayer bridging structures between metal ions and heteroatoms within the defective carbon matrix. The photothermal shock resistance of the LDGF film stems from the interfacial adhesion established through local substrate re-deposition and is further enhanced by the mechanical reinforcement imparted by metal ion bridges. Meanwhile, LDGF exhibits outstanding optical absorption performance (200–1200 nm, >91.99 %), coupled with extremely low light transmittance (<0.01 %). Experiments further demonstrate that LDGF reduces the photonic debonding threshold for identical bonding pairs by approximately 41 %, significantly broadening the applicability and operational window of photonic debonding processes. This laser-induced doping graphitization strategy provides an innovative and feasible material preparation pathway for photothermal conversion layers required in wafer-level and panel-level photonic debonding technologies for advanced packaging.

在玻璃基板上构建结构稳定、附着力优异的掺杂碳基多功能薄膜是当代材料加工领域的核心挑战和研究热点。传统的高温制备工艺往往存在掺杂颗粒老化和团聚的问题，导致薄膜结构均匀性降低，严重限制了其在广谱光吸收和高效热管理方面的应用潜力。本文提出了一种基于区域限制效应的激光诱导掺杂石墨薄膜（LDGF）原位制备方法，实现了在玻璃表面一步构建多功能释放层。该方法利用紫外激光诱导的局域瞬态热场和非平衡动力学来促进缺陷碳基体中金属离子和杂原子之间形成稳定的层间桥接结构。LDGF薄膜的抗光热冲击性能源于通过局部衬底再沉积建立的界面附着力，并通过金属离子桥传递的机械增强进一步增强。同时，LDGF具有出色的光吸收性能（200-1200 nm, >91.99 %）和极低的透光率（<0.01 %）。实验进一步表明，LDGF将相同键对的光子脱键阈值降低了约41% %，显著拓宽了光子脱键过程的适用性和操作窗口。这种激光诱导掺杂石墨化策略为先进封装的晶片级和面板级光子脱粘技术所需的光热转换层提供了一种创新和可行的材料制备途径。

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引用次数: 0

Synchronous multidirectional extrusion based on uniaxial load assembled toggle-arm mechanisms: A case study on 2195 Al-Li alloy 基于单轴载荷组合切换臂机构的同步多向挤压：以2195铝锂合金为例

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-16 DOI: 10.1016/j.jmatprotec.2026.119221

Peng Jia , Xusheng Chang , Xiaoyu Shen , Zhuoxun Yi , Yushi Qi , Gang Chen , Qiang Chen

Synchronous extrusion from independent directions for each port is a potential approach for manufacturing multidirectional structural components (MDSCs). However, its universality and flexibility are limited by the need for specific forming devices, and the accuracy constraints of these devices may lead to folding defects and non-uniform microstructures. To address these challenges, this study proposes a synchronous multidirectional extrusion (SMDE) method based on uniaxial load. The uniaxial load is synchronously decomposed and redirected into multiple independent movements by toggle-arm mechanisms. This method allows excellent flexibility in manufacturing MDSCs since almost arbitrary load direction is available by adjusting the angle and size of the toggle-arm. Moreover, the load synchrony will be easier enabled by the rigidity of toolsets rather than the accuracy of the devices. The feasibility of SMDE was demonstrated by manufacturing an MDSC with square ports and orthogonal ribs using 2195 aluminum-lithium alloy. The investigations in material flow and microstructures at different forming stages revealed non-uniform forming mechanisms influenced by the nonlinear kinematic characteristics and multidirectional discrepancies. Results show that the progressive reduction in horizontal velocity, combined with additional compression, reduces inter-directional variations in height of thin-walled ports, improving the dimensional accuracy. Meanwhile, the active control of nonuniform deformation with additional compression promotes uniform dynamic recrystallization and grain refinement, leading to uniform microstructures and near-isotropic properties across the ports. The average yield strength, ultimate tensile strength, and elongation were tested to be 487.4 MPa, 529.4 MPa and 8.2 %, respectively. Moreover, the strength heterogeneity of the tested ports was calculated to below 1.39 %. This work provides theoretical and experimental guidance for optimizing of multidirectional load paths and actively controlling nonuniform deformation, and offers a novel and efficient method for the precision forming of MDSCs with arbitrary orientations.

从每个端口的独立方向同步挤压是制造多向结构部件（MDSCs）的潜在方法。然而，其通用性和灵活性受到特定成形装置需求的限制，这些装置的精度约束可能导致折叠缺陷和不均匀的微观结构。为了解决这些挑战，本研究提出了一种基于单轴载荷的同步多向挤压（SMDE）方法。通过切换臂机构，将单轴载荷同步分解并重定向为多个独立的运动。这种方法在制造MDSCs方面具有优异的灵活性，因为通过调整切换臂的角度和尺寸，几乎可以实现任意负载方向。此外，负载同步将更容易通过工具集的刚性而不是设备的精度实现。以2195铝锂合金为材料，制备了方孔正交肋MDSC，验证了SMDE的可行性。对不同成形阶段的材料流动和微观组织的研究揭示了受非线性运动特性和多向差异影响的非均匀成形机制。结果表明，水平速度的逐渐减小，加上附加压缩，减小了薄壁孔口高度的方向变化，提高了尺寸精度。同时，主动控制非均匀变形和额外压缩促进了均匀的动态再结晶和晶粒细化，导致了均匀的显微组织和近各向同性的性能。平均屈服强度为487.4 MPa，极限抗拉强度为529.4 MPa，延伸率为8.2 %。此外，计算出测试端口的强度异质性小于1.39 %。该研究为多向加载路径的优化和非均匀变形的主动控制提供了理论和实验指导，为任意取向MDSCs的精密成形提供了一种新颖有效的方法。

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引用次数: 0

Melt pool characteristics and microstructure evolution during laser-directed energy deposition of Ni-based superalloy on single-crystal substrates 单晶基镍基高温合金激光定向能沉积熔池特征及显微组织演变

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-15 DOI: 10.1016/j.jmatprotec.2026.119222

Xuewei Yan , Wenxue Hu , Zhao Zhao , Zheng Chen , Dejian Sun , Qingyan Xu

Repairing single-crystal superalloy components with cost-effective polycrystalline alloy represents a significant metallurgical challenge, primarily due to the difficulty in suppressing stray grain formation during epitaxial growth. This study investigated the deposition of IN718 onto DD6 single-crystal substrates via laser-directed energy deposition. An orthogonal design for single-track experiments was first employed to optimize the processing window, achieving a maximum epitaxial ratio of 0.455. To reveal the solidification mechanisms governing stray grain formation, the melt pool dynamics and thermal history were analyzed using a coupled thermo-fluid model. A critical processing-microstructure correlation was identified in single-layer deposition: increasing the overlap ratio from 35 % to 50 % induced a marked increase in stray grain fraction, which is contrary to conventional expectations. Mechanism analysis reveals that this mainly stems from the evolution of melt pool geometry; the altered curvature of the fusion boundary reorients the local thermal gradient vectors, thereby changing the tendency of oriented-to-misoriented transition and columnar-to-equiaxed transition at the track overlap regions. Guided by these mechanistic insights, a multi-layer deposition strategy was developed to maintain the thermal conditions required for continuous epitaxial growth. These findings offer critical insights into the microstructural control mechanisms governing the hybrid repair of single-crystal components with dissimilar alloys.

用低成本的多晶合金修复单晶高温合金部件是一项重大的冶金挑战，主要是因为在外延生长过程中难以抑制杂散晶粒的形成。本研究采用激光定向能沉积的方法在DD6单晶衬底上沉积IN718。首先采用单径实验正交设计优化处理窗口，得到最大外延比0.455。为了揭示控制杂散晶粒形成的凝固机制，采用热-流体耦合模型对熔池动力学和热历史进行了分析。在单层沉积中发现了关键的加工-微观结构相关性：将重叠比从35 %增加到50 %，会导致杂散粒分数显著增加，这与传统的预期相反。机理分析表明，这主要源于熔池几何形态的演变；融合边界曲率的改变改变了局部热梯度矢量的方向，从而改变了轨迹重叠区域的定向向错取向转变和柱状向等轴转变的趋势。在这些机理的指导下，研究人员开发了一种多层沉积策略，以保持连续外延生长所需的热条件。这些发现对控制不同合金单晶部件混合修复的微观结构控制机制提供了重要的见解。

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引用次数: 0

A novel magnetically driven impact treatment for internal surface enhancement of titanium tubes 一种新型磁驱动冲击强化钛管内表面处理方法

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-13 DOI: 10.1016/j.jmatprotec.2026.119218

Chongrui Wang , Yu Zhang , Siyu Tian , Zhanjie Zhang , Jiong Zhang

Achieving controllable impact-induced plastic deformation in geometrically confined internal cavities remains a fundamental challenge in advanced surface engineering. Here, a magnetically driven impact treatment (MDIT) is proposed as a model experimental platform, in which specially engineered magnetic core–shell shots driven by an external rotating magnetic field enable uniform and repeatable impacts on internal surfaces. In contrast to conventional techniques such as roller/ball-burnishing, ultrasonic shot peening, or surface mechanical attrition treatment, which are largely restricted to external surfaces and often deteriorate surface finish, the MDIT process developed here enables the simultaneous enhancement of surface hardness and surface finish. Experimental results on commercially pure titanium (CP-Ti) tubes show the formation of a surface gradient layer approximately 20–30 μm thick, with a 130 % increase in surface hardness and a tenfold reduction in surface roughness (Ra: 1.11 μm to 0.13 μm). Microstructural analysis reveals dense dislocation networks and deformation twins in the subsurface layer, indicating that twin–dislocation substructures, rather than grain refinement, dominate the strengthening mechanism. Real-time force monitoring confirms process stability with impact frequencies of ∼200 Hz. Beyond the specific configuration studied, the findings provide transferable insights into impact-based surface processing, with implications for strengthening and finishing different metallic materials, as well as tubular components used in aerospace, nuclear energy, and biomedical systems.

在几何受限的内腔中实现可控的冲击诱发塑性变形仍然是先进表面工程的一个基本挑战。本文提出了一种磁驱动冲击处理（MDIT）作为模型实验平台，在该实验平台中，由外部旋转磁场驱动的特殊工程磁芯-壳弹丸可以对内表面进行均匀且可重复的冲击。传统的技术，如滚轮/球抛光、超声波喷丸或表面机械摩擦处理，很大程度上局限于外部表面，通常会降低表面光洁度，与之相反，这里开发的MDIT工艺可以同时提高表面硬度和表面光洁度。实验结果表明，纯钛（CP-Ti）管表面形成了20 ~ 30 μm厚的梯度层，表面硬度提高了130% %，表面粗糙度降低了10倍（Ra: 1.11 μm ~ 0.13 μm）。显微组织分析表明，在近地层中存在密集的位错网络和变形孪晶，表明双位错亚结构而非晶粒细化主导了强化机制。实时力监测确认了冲击频率为~ 200 Hz的过程稳定性。除了研究的具体配置外，研究结果还为基于冲击的表面处理提供了可转移的见解，对加强和精加工不同的金属材料以及用于航空航天，核能和生物医学系统的管状部件具有重要意义。

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引用次数: 0

The regulation mechanism of processing parameters on the microstructural evolution and mechanical properties of 7A52 aluminum alloy fabricated by additive friction stir deposition 研究了工艺参数对添加剂搅拌摩擦沉积制备7A52铝合金组织演变及力学性能的调控机理

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-13 DOI: 10.1016/j.jmatprotec.2026.119220

Huan Liu , Huanyong Cui , Zongqing Ma , Chengcheng Shi , Wenhao Shang , Hongjia Zhang , Guannan Chu , Xiangxue Li , Guofeng Han

Additive friction stir deposition (AFSD) represents a novel additive manufacturing (AM) technique with significant potential for producing Al-Zn-Mg-Cu alloys, which helps overcome common issues such as thermal cracking and porosity associated with traditional AM. This study systematically investigates the relationships between heat input, process parameters, microstructure, and mechanical properties. Research indicates that heat input determines the microstructural characteristics of AFSD deposition layers by regulating the relative dominance of dynamic recrystallisation and dynamic recovery. Due to the intense thermo-mechanical coupling during AFSD, the grains within the deposited layer are significantly refined, with an average grain size reaching 2.68 μm under the optimized parameters. Meanwhile, under high temperature and plastic deformation, a part of the coarse Al₂FeSi phase in the feedstock fractures, while a part of it transforms into the α-Al₁₂(Fe, Mn)₃Si phase with the involvement of Mn elements. The ultrafine grains, high-density dislocations, and fragmented second-phase particles generated during the AFSD, significantly enhance the diffusion rate of solute atoms. Meanwhile, the high-temperature environment induced by the deposition process induce partial dissolution of precipitates, allowing AFSD-fabricated 7A52 alloy to achieve complete solution treatment within an extremely short timeframe. The deposits subjected to a short-duration solution treatment followed by aging exhibited a yield strength of 488.36 MPa, an ultimate tensile strength of 535.27 MPa, and an elongation of 12.83 %. This work systematically investigates the optimization of the AFSD process, providing a solid theoretical foundation and practical guidance for fabricating high-strength aluminum alloys using AFSD.

添加剂搅拌摩擦沉积（AFSD）是一种新型的增材制造（AM）技术，具有生产Al-Zn-Mg-Cu合金的巨大潜力，有助于克服传统增材制造相关的常见问题，如热裂和气孔。本研究系统地探讨了热输入、工艺参数、微观结构和力学性能之间的关系。研究表明，热输入通过调节动态再结晶和动态恢复的相对优势决定了AFSD沉积层的微观组织特征。由于AFSD过程中强烈的热-力耦合作用，沉积层内晶粒明显细化，在优化参数下，平均晶粒尺寸达到2.68 μm。同时，在高温和塑性变形作用下，原料中的一部分粗Al2FeSi相断裂，一部分在Mn元素的参与下转变为α-Al12(Fe, Mn)3Si相。AFSD过程中产生的超细晶粒、高密度位错和破碎的第二相颗粒显著提高了溶质原子的扩散速率。同时，沉积过程产生的高温环境诱导析出相部分溶解，使afsd制备的7A52合金在极短的时间内实现完全固溶处理。经短时间固溶后时效处理的镀层屈服强度为488.36 MPa，极限抗拉强度为535.27 MPa，伸长率为12.83 %。本工作系统地研究了AFSD工艺的优化，为利用AFSD制备高强度铝合金提供了坚实的理论基础和实践指导。

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引用次数: 0

Immiscible Cu-W and Cu-Nb composites processed by pellet-based laser additive manufacturing 激光增材制造非混相Cu-W和Cu-Nb复合材料

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-12 DOI: 10.1016/j.jmatprotec.2026.119217

Rakesh Das , Pawan Kumar Dubey , Nirmal Kumar Katiyar , Vidhyadhar Mishra , Suman Sarkar , Suman Sarkar , Indranil Manna , Suman Chakraborty , Chandra Sekhar Tiwary

The current study investigated pellet-assisted laser powder bed fusion (LPBF) as an effective approach to fabricate immiscible Copper-Tungsten (Cu-W) and Copper-Niobium (Cu-Nb) composites, enabling tunable microstructures and enhanced properties. While Cu-based immiscible composites are attractive for their mechanical, wear, and thermal performance, their fabrication remains a long-standing challenge due to phase segregation. Additive manufacturing (AM) offers a pathway to overcome these challenges, yet systematic studies on immiscible systems are still limited. In this study, compacted powder pellets were processed by laser melting under optimized parameters (laser power, laser head speed) to achieve complete melting of the Cu matrix, while preserving W and Nb as solid dispersoids. The addition of W and Nb significantly altered solidification behaviors, inducing equiaxed-columnar transitions and non-linear property trends. Cu-Nb composites exhibited yield strengths of 23–66 MPa, while Cu-W composites reached 74–124 MPa, both outperforming LPBF Cu (∼38 MPa). Thermal transport was markedly improved, with temperature gradients reduced from 8.8 °C (pure Cu) to 4.4 °C (Cu-2wt%W) and 3.8 °C (Cu-2wt%Nb). Wear resistance and coefficient of friction (COF) were also enhanced. To rationalize microstructure evolution and secondary reinforcement distribution, a three-dimensional (3D) Discrete Element Method-Computational Fluid Dynamics (DEM-CFD) model was developed, providing mechanistic insight into melt pool dynamics, temperature variation, and dispersoid distribution. Fundamentally, this study establishes pellet-assisted LPBF with laser parameter optimization as a generic processing pathway for immiscible alloys, offering a transferable framework to control microstructural evolution and achieve tailored properties in otherwise incompatible material systems.

目前的研究研究了颗粒辅助激光粉末床熔融（LPBF）作为一种有效的方法来制造非混相铜钨（Cu-W）和铜铌（Cu-Nb）复合材料，实现可调的微观结构和增强的性能。虽然铜基非混相复合材料因其机械、磨损和热性能而具有吸引力，但由于相偏析，其制造仍然是一个长期存在的挑战。增材制造（AM）为克服这些挑战提供了一条途径，但对非混相系统的系统研究仍然有限。本研究在优化参数（激光功率、激光头速度）下，对压实的粉末颗粒进行激光熔化处理，使Cu基体完全熔化，同时保留W和Nb作为固体分散体。W和Nb的加入显著改变了凝固行为，诱导了等轴-柱状转变和非线性性能趋势。Cu- nb复合材料的屈服强度为23-66 MPa， Cu- w复合材料的屈服强度为74-124 MPa，均优于LPBF Cu（~ 38 MPa）。热传递明显改善，温度梯度从8.8°C（纯Cu）降至4.4°C （Cu-2wt%W）和3.8°C （Cu-2wt%Nb）。耐磨性和摩擦系数（COF）也得到了提高。为了使微观结构演变和二次钢筋分布合理化，建立了三维（3D）离散元法-计算流体动力学（DEM-CFD）模型，为熔池动力学、温度变化和弥散分布提供了机制洞察。从根本上说，本研究建立了带有激光参数优化的颗粒辅助LPBF作为非混相合金的通用加工途径，提供了一个可转移的框架来控制微观结构演变，并在其他不相容的材料系统中实现量身定制的性能。

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引用次数: 0

A theoretical model for predicting multi-cracking susceptibility in Ni-based superalloys fabricated by additive manufacturing 增材制造镍基高温合金多重裂纹敏感性预测的理论模型

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-12 DOI: 10.1016/j.jmatprotec.2026.119219

Mingjie Li, Fu Wang, Qiang Yang, Dichen Li

Aiming to predict the occurrence of cracks in additively manufactured (AM) Ni-based superalloys, this study proposed a novel integrated multi-cracking susceptibility model and index (CSI). The model comprehensively accounts for key thermophysical and microstructural factors, including the viscosity of the alloy melt, the presence of carbides and γ/γ΄ eutectic, as well as the influence of stacking fault energy and grain boundary (GB) energy on crack formation during rapid solidification of AM. To experimentally validate the susceptibility model, CM247LC superalloys with varied (Hf+C) contents were fabricated via laser-based powder bed fusion (LB-PBF), with their cracking behavior systematically quantified. Predictions revealed that crack susceptibility initially decreased and then increased with rising (Hf+C) content, fully corroborated by experimental results. Notably, the addition of 1 wt% (Hf+C) resulted in a significant reduction in cracks, yielding minimum crack length and area densities of 0.004 mm/mm² and 0.017 %, respectively. The healing effect on cracks is attributed to two synergistic mechanisms: the backfilling effect of the Hf-rich eutectics into cracks and the dispersion-strengthening effect of more fine carbides along the GBs. The predictive capability and generalizability of the proposed CSIs were validated via literature-derived machine learning, demonstrating that CSI_SC achieves 20 % higher accuracy than Kou’s classical criterion. The developed model shows significant potential for capturing the complex cracking behavior and guiding the design of crack-free AM superalloys.

为了预测增材制造镍基高温合金裂纹的发生，提出了一种新的综合多裂纹敏感性模型和指数（CSI）。该模型综合考虑了合金熔体粘度、碳化物和γ/γ΄共晶的存在以及层错能和晶界能对AM快速凝固过程中裂纹形成的影响等关键热物理和显微组织因素。为了实验验证磁化率模型，采用激光粉末床熔合法制备了不同（Hf+C）含量的CM247LC高温合金，并对其开裂行为进行了系统量化。预测结果表明，随着（Hf+C）含量的增加，裂纹敏感性先降低后增加，实验结果与预测结果完全一致。值得注意的是，添加1 wt% （Hf+C）可以显著减少裂纹，最小裂纹长度和面积密度分别为0.004 mm/mm2和0.017 %。对裂纹的修复作用可归因于两种协同机制：富hf共晶对裂纹的回填作用和更细碳化物沿GBs的弥散强化作用。通过文献衍生的机器学习验证了所提出的CSIs的预测能力和通用性，表明cssc比Kou的经典准则的准确率高出20% %。所建立的模型对于捕获复杂的裂纹行为和指导无裂纹AM高温合金的设计具有重要的潜力。

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引用次数: 0