Pub Date : 2025-12-05DOI: 10.1016/j.jmatprotec.2025.119174
Shuai Liu , Xin Wen , Changsheng Liu , Zhikang Xia , Yongqiang Wang , Chao Yuan
High-temperature thermal-field-assisted additive manufacturing (AM) has been applied to several γ′-rich Ni-based superalloys, yet a generalizable parameter selection scheme, quantitative defect regime mapping, and fundamental understanding of microstructural evolution remain elusive. Here, IN713LC is used as a representative alloy and fabricated via induction-heating-assisted laser directed energy deposition (IH-LDED) to address these gaps. Crack-free and dense builds were achieved at process temperatures between the γ′ precipitation threshold and the solidus, using 70–80 % of the theoretical melting energy density. A crack-type competition mechanism, governed by the coupling of temperature and energy density, was revealed. Elevated temperatures promoted γ′ homogenization and eliminated γ/γ′ eutectic, suppressing liquation cracking and preventing ductility-dip cracking. Strain-age cracking was dominated by notch effects, transformation stresses, or thermal stresses under different conditions. Low energy input caused local oxidation, whereas super-solidus temperatures triggered rapid semi-solid oxidation and a novel feedback loop, both leading to oxidation-induced cracking. As process temperature increased, solute-driven differential lattice expansion modified γ/γ′ misfit from 1.1 % at 1100°C to −4.1 % at 1200°C, strengthening the coherent strain field. This shifted γ′–dislocation interactions from long-range cooperative shearing to short-range shearing and Orowan bypass, enabling tailored strength–ductility combinations. These findings establish a generic process–defect–microstructure–performance framework, offering mechanistic and transferable insights into additive manufacturing of non-weldable superalloys (e.g., performance customization and quantitative defect analysis).
{"title":"Crack-free additive manufacturing of Ni-based superalloy IN713LC with enhanced performance via high-temperature thermal field assistance","authors":"Shuai Liu , Xin Wen , Changsheng Liu , Zhikang Xia , Yongqiang Wang , Chao Yuan","doi":"10.1016/j.jmatprotec.2025.119174","DOIUrl":"10.1016/j.jmatprotec.2025.119174","url":null,"abstract":"<div><div>High-temperature thermal-field-assisted additive manufacturing (AM) has been applied to several γ′-rich Ni-based superalloys, yet a generalizable parameter selection scheme, quantitative defect regime mapping, and fundamental understanding of microstructural evolution remain elusive. Here, IN713LC is used as a representative alloy and fabricated via induction-heating-assisted laser directed energy deposition (IH-LDED) to address these gaps. Crack-free and dense builds were achieved at process temperatures between the γ′ precipitation threshold and the solidus, using 70–80 % of the theoretical melting energy density. A crack-type competition mechanism, governed by the coupling of temperature and energy density, was revealed. Elevated temperatures promoted γ′ homogenization and eliminated γ/γ′ eutectic, suppressing liquation cracking and preventing ductility-dip cracking. Strain-age cracking was dominated by notch effects, transformation stresses, or thermal stresses under different conditions. Low energy input caused local oxidation, whereas super-solidus temperatures triggered rapid semi-solid oxidation and a novel feedback loop, both leading to oxidation-induced cracking. As process temperature increased, solute-driven differential lattice expansion modified γ/γ′ misfit from 1.1 % at 1100°C to −4.1 % at 1200°C, strengthening the coherent strain field. This shifted γ′–dislocation interactions from long-range cooperative shearing to short-range shearing and Orowan bypass, enabling tailored strength–ductility combinations. These findings establish a generic process–defect–microstructure–performance framework, offering mechanistic and transferable insights into additive manufacturing of non-weldable superalloys (e.g., performance customization and quantitative defect analysis).</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"348 ","pages":"Article 119174"},"PeriodicalIF":7.5,"publicationDate":"2025-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145749018","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 high-temperature performance of current additively manufactured IN 718 alloy is critically limited by synergistic effects of surface-topography-induced stress concentrators, and subcritical porosity, particularly the thermal softening of the γ″ phase and its heterogeneous distribution within grains at 650 °C. Here, we propose a laser polishing treatment strategy that reconstructs both surface and sub-surface architecture of LPBF Inconel 718 alloy. This approach significantly reduces surface roughness from Ra ≥ 10 µm to Ra ≤ 1 µm, eliminates near-surface porosity by up to 65.7 %, and forms a refined, uniform nanometric dislocation cell. High-temperature tensile tests demonstrate plasticity performance nearly doubled at 650 °C with only 3 % yield strength loss. The detailed fractographic and microstructural analyses have confirmed that the enhanced plasticity originates from: (1) stabilized dislocation cell structures that homogenize stress distribution and suppress grain boundary cracking, (2) elimination of columnar grain morphology through dynamic recrystallization, and (3) delayed crack initiation and propagation between 550 and 650 ℃ due to dislocation cell structural confinement. Laser polishing produces a near-surface dislocation-cell structure engineering emerges as a transformative post-processing strategy, enabling additively manufactured IN718 alloy to overcome intrinsic high-temperature limitations through dislocation cell, thus redefining the strength-ductility paradigm at elevated temperatures.
{"title":"Laser polishing of LPBF IN718 forms dislocation cells and enhances high temperature ductility","authors":"Qirui Zhang , Xing Li , Mingze Xin , Yingchun Guan","doi":"10.1016/j.jmatprotec.2025.119175","DOIUrl":"10.1016/j.jmatprotec.2025.119175","url":null,"abstract":"<div><div>The high-temperature performance of current additively manufactured IN 718 alloy is critically limited by synergistic effects of surface-topography-induced stress concentrators, and subcritical porosity, particularly the thermal softening of the γ″ phase and its heterogeneous distribution within grains at 650 °C. Here, we propose a laser polishing treatment strategy that reconstructs both surface and sub-surface architecture of LPBF Inconel 718 alloy. This approach significantly reduces surface roughness from Ra ≥ 10 µm to Ra ≤ 1 µm, eliminates near-surface porosity by up to 65.7 %, and forms a refined, uniform nanometric dislocation cell. High-temperature tensile tests demonstrate plasticity performance nearly doubled at 650 °C with only 3 % yield strength loss. The detailed fractographic and microstructural analyses have confirmed that the enhanced plasticity originates from: (1) stabilized dislocation cell structures that homogenize stress distribution and suppress grain boundary cracking, (2) elimination of columnar grain morphology through dynamic recrystallization, and (3) delayed crack initiation and propagation between 550 and 650 ℃ due to dislocation cell structural confinement. Laser polishing produces a near-surface dislocation-cell structure engineering emerges as a transformative post-processing strategy, enabling additively manufactured IN718 alloy to overcome intrinsic high-temperature limitations through dislocation cell, thus redefining the strength-ductility paradigm at elevated temperatures.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"348 ","pages":"Article 119175"},"PeriodicalIF":7.5,"publicationDate":"2025-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145749021","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 : 2025-12-05DOI: 10.1016/j.jmatprotec.2025.119173
Min Dou , Shouyi Sun , Huitao Chen , Tianyu Yuan , Xinmei Wang , Lei Li
This study investigates the effects of Laser Shock Peening (LSP) on the mechanisms of surface plastic deformation in nickel-based single-crystal (NBSC) superalloys. After LSP at 5–9 J, no grain boundaries are introduced, and the single-crystal (SC) characteristics of the material are still retained. Severe plastic deformation occurs accompanied by the formation of a millimeter-scale work-hardened layer (the hardness could increase by 53.8%). In addition, the periodic structures formed on the surface lead to a maximum increase in surface roughness by approximately 8.1-fold. The deformed surface layer comprises a severe plastic deformation layer (SPDL) and a mild plastic deformation layer (MPDL). Within the SPDL, LSP activates the {111}<110> octahedral slip systems, generating high-density <110>-oriented cross-slip bands and characteristic dislocation configurations such as stacking faults (SFs), dislocation walls (DWs), dislocation tangles (DTs), and dislocation networks, thereby increasing the geometrically necessary dislocation (GND) density. At 10 J, localized remelting zones caused by thermal effects are also involved in the plastic deformation process, resulting in a reduction in the SPDL depth and GND density. Nevertheless, the γ matrix phase exhibits a significantly higher dislocation density than the γ' precipitate phase for all LSP-treated samples. This discovery provides critical mechanistic support and parameter guidance for the engineering applications of LSP in the precise surface modification of SC alloys.
{"title":"Effect of laser energy on surface deformation mechanism of Nickel-based single-crystal superalloy subject to Laser shock peening","authors":"Min Dou , Shouyi Sun , Huitao Chen , Tianyu Yuan , Xinmei Wang , Lei Li","doi":"10.1016/j.jmatprotec.2025.119173","DOIUrl":"10.1016/j.jmatprotec.2025.119173","url":null,"abstract":"<div><div>This study investigates the effects of Laser Shock Peening (LSP) on the mechanisms of surface plastic deformation in nickel-based single-crystal (NBSC) superalloys. After LSP at 5–9 J, no grain boundaries are introduced, and the single-crystal (SC) characteristics of the material are still retained. Severe plastic deformation occurs accompanied by the formation of a millimeter-scale work-hardened layer (the hardness could increase by 53.8%). In addition, the periodic structures formed on the surface lead to a maximum increase in surface roughness by approximately 8.1-fold. The deformed surface layer comprises a severe plastic deformation layer (SPDL) and a mild plastic deformation layer (MPDL). Within the SPDL, LSP activates the {111}<110> octahedral slip systems, generating high-density <110>-oriented cross-slip bands and characteristic dislocation configurations such as stacking faults (SFs), dislocation walls (DWs), dislocation tangles (DTs), and dislocation networks, thereby increasing the geometrically necessary dislocation (GND) density. At 10 J, localized remelting zones caused by thermal effects are also involved in the plastic deformation process, resulting in a reduction in the SPDL depth and GND density. Nevertheless, the γ matrix phase exhibits a significantly higher dislocation density than the γ' precipitate phase for all LSP-treated samples. This discovery provides critical mechanistic support and parameter guidance for the engineering applications of LSP in the precise surface modification of SC alloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"348 ","pages":"Article 119173"},"PeriodicalIF":7.5,"publicationDate":"2025-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145749020","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 : 2025-12-05DOI: 10.1016/j.jmatprotec.2025.119176
Yuqing Liu , Jiawen Luo , Zhe Feng , Siyu Zhang , Zhiwei Hao , Yijie Peng , Wei Fan , Hua Tan , Fengying Zhang , Xin Lin
Coated-graphene nanoplatelets (GNPs) can effectively reduce graphene agglomeration and enhance the thermal conductivity of aluminum metal matrix composites (AMMCs). Thus, laser additive manufacturing (LAM) of coated-GNPs reinforced AMMCs holds great promise for producing lightweight, high thermal conductivity, and complex thermal management structures. However, current powder preparation processes lead to graphene agglomeration, limiting thermal conductivity improvement. Moreover, laser remelting can potentially enhance metallurgical quality and thermal conductivity. Therefore, this study develops LAM-processed Cu-GNPs/AlSi7Mg composite based on optimized powder preparation and remelting strategy. Under combined ultrasonic oscillation and mechanical stirring, 0.5 wt% and 1.5 wt% Cu-GNPs/AlSi7Mg composites (containing 0.1 wt% and 0.3 wt% GNPs) were prepared using chemical Cu plating. The combined mixing ensured uniform graphene dispersion and improved powder flowability, while remelting further reduced defects and enhanced densification. The Cu-GNPs distributed along the grain boundaries promoted component supercooling, resulting in grain refinement and proportion increase of equiaxial grains. Both Cu-GNPs and remelting raised the proportion of heat-affected zones (HAZ) per unit area, where fractured Al-Si eutectic and precipitated Si resulted in lower thermal resistance. In addition, Cu-GNPs established phonon conduction pathways at boundaries, thereby improving grain boundary heat transfer efficiency. Consequently, at 25°C, the thermal conductivity of 1.5 wt% Cu-GNPs/AlSi7Mg reached 156.4 W/(m·K), representing an increase of 23.9 % over AlSi7Mg. Through the synergistic optimization of dispersion, interfacial bonding strength, and metallurgical quality, the thermal conductivity of LAM-ed AlSi7Mg and other Cu-coated GNPs-reinforced systems is effectively improved. This paper provides critical theoretical and technical foundations for engineering applications of thermal management structures.
{"title":"Laser additive manufactured high thermal conductivity Cu-GNPs/AlSi7Mg composite based on powder preparation and remelting strategy","authors":"Yuqing Liu , Jiawen Luo , Zhe Feng , Siyu Zhang , Zhiwei Hao , Yijie Peng , Wei Fan , Hua Tan , Fengying Zhang , Xin Lin","doi":"10.1016/j.jmatprotec.2025.119176","DOIUrl":"10.1016/j.jmatprotec.2025.119176","url":null,"abstract":"<div><div>Coated-graphene nanoplatelets (GNPs) can effectively reduce graphene agglomeration and enhance the thermal conductivity of aluminum metal matrix composites (AMMCs). Thus, laser additive manufacturing (LAM) of coated-GNPs reinforced AMMCs holds great promise for producing lightweight, high thermal conductivity, and complex thermal management structures. However, current powder preparation processes lead to graphene agglomeration, limiting thermal conductivity improvement. Moreover, laser remelting can potentially enhance metallurgical quality and thermal conductivity. Therefore, this study develops LAM-processed Cu-GNPs/AlSi7Mg composite based on optimized powder preparation and remelting strategy. Under combined ultrasonic oscillation and mechanical stirring, 0.5 wt% and 1.5 wt% Cu-GNPs/AlSi7Mg composites (containing 0.1 wt% and 0.3 wt% GNPs) were prepared using chemical Cu plating. The combined mixing ensured uniform graphene dispersion and improved powder flowability, while remelting further reduced defects and enhanced densification. The Cu-GNPs distributed along the grain boundaries promoted component supercooling, resulting in grain refinement and proportion increase of equiaxial grains. Both Cu-GNPs and remelting raised the proportion of heat-affected zones (HAZ) per unit area, where fractured Al-Si eutectic and precipitated Si resulted in lower thermal resistance. In addition, Cu-GNPs established phonon conduction pathways at boundaries, thereby improving grain boundary heat transfer efficiency. Consequently, at 25°C, the thermal conductivity of 1.5 wt% Cu-GNPs/AlSi7Mg reached 156.4 W/(m·K), representing an increase of 23.9 % over AlSi7Mg. Through the synergistic optimization of dispersion, interfacial bonding strength, and metallurgical quality, the thermal conductivity of LAM-ed AlSi7Mg and other Cu-coated GNPs-reinforced systems is effectively improved. This paper provides critical theoretical and technical foundations for engineering applications of thermal management structures.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"348 ","pages":"Article 119176"},"PeriodicalIF":7.5,"publicationDate":"2025-12-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145749019","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 : 2025-12-03DOI: 10.1016/j.jmatprotec.2025.119164
Jilai Wang , Chuanzheng Li , Haotian Gong , Zhutian Xu , Yi Wan
The coating-then-forming process offers a promising route to improve the manufacturing efficiency of metallic bipolar plates in proton exchange membrane fuel cells. However, fracture of ultrathin coatings during forming presents a formidable challenge to the corrosion resistance of coated metallic sheets. To provide theoretical guidance for addressing this issue, this work investigates the coating fracture behavior during the micro-channel forming process through experiments and numerical analysis. Coating cracks were revealed to be concentrated within the fillet and flat regions of the channel ridge, highly sensitive to local strain levels governed by both channel geometry and substrate microstructure. Therefore, a full-field simulation methodology was developed to predict the coating fracture during forming, balancing between computational efficiency with accuracy. Within this numerical framework, hybrid modeling of the metallic sheet substrate was employed, combining local implementation of crystal plasticity in the critical region with homogeneous materials elsewhere. For coating on the critical region, varying failure parameters correlated with substrate microstructure were determined by the microscopic fracture mechanism. Experimental validation confirms that the developed model can precisely predict both coating fractures and formed profiles, notably achieving an 80 % accuracy improvement in crack density compared to conventional approaches. Based on the simulation results, process windows were established to correlate coating fracture and channel geometry with forming parameters, thereby guiding optimization toward the minimization of crack density under geometrical constraints. Following parameter optimization, coating cracks were successfully eliminated at the flat region, demonstrating an effective strategy for maintaining the corrosion resistance after forming.
{"title":"Fracture of ultrathin coating during micro-channel forming process of coated metallic sheet: Experiments and numerical prediction","authors":"Jilai Wang , Chuanzheng Li , Haotian Gong , Zhutian Xu , Yi Wan","doi":"10.1016/j.jmatprotec.2025.119164","DOIUrl":"10.1016/j.jmatprotec.2025.119164","url":null,"abstract":"<div><div>The coating-then-forming process offers a promising route to improve the manufacturing efficiency of metallic bipolar plates in proton exchange membrane fuel cells. However, fracture of ultrathin coatings during forming presents a formidable challenge to the corrosion resistance of coated metallic sheets. To provide theoretical guidance for addressing this issue, this work investigates the coating fracture behavior during the micro-channel forming process through experiments and numerical analysis. Coating cracks were revealed to be concentrated within the fillet and flat regions of the channel ridge, highly sensitive to local strain levels governed by both channel geometry and substrate microstructure. Therefore, a full-field simulation methodology was developed to predict the coating fracture during forming, balancing between computational efficiency with accuracy. Within this numerical framework, hybrid modeling of the metallic sheet substrate was employed, combining local implementation of crystal plasticity in the critical region with homogeneous materials elsewhere. For coating on the critical region, varying failure parameters correlated with substrate microstructure were determined by the microscopic fracture mechanism. Experimental validation confirms that the developed model can precisely predict both coating fractures and formed profiles, notably achieving an 80 % accuracy improvement in crack density compared to conventional approaches. Based on the simulation results, process windows were established to correlate coating fracture and channel geometry with forming parameters, thereby guiding optimization toward the minimization of crack density under geometrical constraints. Following parameter optimization, coating cracks were successfully eliminated at the flat region, demonstrating an effective strategy for maintaining the corrosion resistance after forming.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"348 ","pages":"Article 119164"},"PeriodicalIF":7.5,"publicationDate":"2025-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145693103","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 : 2025-12-03DOI: 10.1016/j.jmatprotec.2025.119165
Huihui Nie , Yangyang Yang , Jinyi Li , Haoran Guo , Wentao Fan , Hongsheng Chen , Jun Zhou , Wenxian Wang
In this work, a novel type of Al/Cu composite tubes were successfully produced by strong staggered spinning with good surface quality, and the effect of thickness reductions on the microstructure and bonding mechanism of interface and the texture evolution of component layers. The results show that the original intermetallics layer in base material (BM) cracks and twists during spinning, and the contact area between fresh Al and Cu increases, resulting in a new diffusion layer containing AlCu, Al2Cu3 and Al4Cu9 phases from Al to Cu matrix, which presents a hardness between Cu and Al and facilitates stress transfer and deformation coordination. Cu atoms show a higher diffusion rate partly because grains, fragments or atomic clusters of Cu are pushed or sheared into Al and partly because abundant GBs and dislocations in Al provide excellent channels for the rapid diffusion of Cu atoms. With the increase of thickness reduction, Cu grains are elongated in S25 % and kinking of deformation zones are formed in S70 %, and the corresponding grain size decreases from 1.45μm to 0.98μm with a {111} < 112 > shear texture. Besides, Cu grains with orientation of < 001 > //AD are more prone to deformation and gradually change their orientation to < 111 > //AD, causing a growth of texture intensity in S70 %. The extent of grain refinement of Al near Cu is larger than that of Al away from the interface owing to the shear effect of interface, and the latter ones change from elongated grains to equiaxial grains as the increase of thickness reduction because of the extensive DRX, resulting Cube {100} < 001 > texture with the highest intensity of 14.1 among the three tubes. Interface delamination is not observed during tensile tests, although the interface microstructure varies. The well-bonded interface, refinement strengthening and work hardening enhance the UTS of S70 % to 172.89 MPa, increasing by 56.7 % compared with that of BM (110.34 MPa).
{"title":"Effect of thickness reduction of strong staggered spinning on the interface microstructure, texture evolution and mechanical properties of Al/Cu composite tubes","authors":"Huihui Nie , Yangyang Yang , Jinyi Li , Haoran Guo , Wentao Fan , Hongsheng Chen , Jun Zhou , Wenxian Wang","doi":"10.1016/j.jmatprotec.2025.119165","DOIUrl":"10.1016/j.jmatprotec.2025.119165","url":null,"abstract":"<div><div>In this work, a novel type of Al/Cu composite tubes were successfully produced by strong staggered spinning with good surface quality, and the effect of thickness reductions on the microstructure and bonding mechanism of interface and the texture evolution of component layers. The results show that the original intermetallics layer in base material (BM) cracks and twists during spinning, and the contact area between fresh Al and Cu increases, resulting in a new diffusion layer containing AlCu, Al<sub>2</sub>Cu<sub>3</sub> and Al<sub>4</sub>Cu<sub>9</sub> phases from Al to Cu matrix, which presents a hardness between Cu and Al and facilitates stress transfer and deformation coordination. Cu atoms show a higher diffusion rate partly because grains, fragments or atomic clusters of Cu are pushed or sheared into Al and partly because abundant GBs and dislocations in Al provide excellent channels for the rapid diffusion of Cu atoms. With the increase of thickness reduction, Cu grains are elongated in S25 % and kinking of deformation zones are formed in S70 %, and the corresponding grain size decreases from 1.45μm to 0.98μm with a {111} < 112 > shear texture. Besides, Cu grains with orientation of < 001 > //AD are more prone to deformation and gradually change their orientation to < 111 > //AD, causing a growth of texture intensity in S70 %. The extent of grain refinement of Al near Cu is larger than that of Al away from the interface owing to the shear effect of interface, and the latter ones change from elongated grains to equiaxial grains as the increase of thickness reduction because of the extensive DRX, resulting Cube {100} < 001 > texture with the highest intensity of 14.1 among the three tubes. Interface delamination is not observed during tensile tests, although the interface microstructure varies. The well-bonded interface, refinement strengthening and work hardening enhance the UTS of S70 % to 172.89 MPa, increasing by 56.7 % compared with that of BM (110.34 MPa).</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"348 ","pages":"Article 119165"},"PeriodicalIF":7.5,"publicationDate":"2025-12-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145665537","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 : 2025-11-29DOI: 10.1016/j.jmatprotec.2025.119163
Yasong Shi , Taitong Jin , Jiawei Ding , Yong Wang , Wei Zhang , Yingbo Peng
The “layer-by-layer” processing nature of laser powder bed fusion (LPBF) presents challenges for the distribution of multi-materials in the horizontal direction, thereby limiting the design flexibility and functionality of multi-material components. In this study, a "powder + entity" interfacial processing model was proposed to achieve intralayer deposition of dissimilar materials via LPBF. In the intralayer deposited SS316L/FeCoCrNi high entropy alloy (HEA)-diamond composites dissimilar-material samples, there was no newly formed phase at the interface, which preserved the γ-austenite and HEA face-centered cubic (FCC) structures, with good interfacial metallurgical bonding. Thermal-fluid coupling simulations showed the asymmetric flow of the mixed molten pool caused by the combined effects of thermal/solute-induced Marangoni flow and gravity, influencing the solidification paths on both sides of the interface. SS316L side characterized by directional melt flow exhibited a preferential crystal-grow orientation that transitioned from < 111 > to < 101 > . Conversely, the composites side displayed anisotropic crystal growth with an increasing dislocation density due to local melt reflux. The interfacial bonding performance of the dissimilar-material samples achieved a yield strength of 430 MPa and a fracture strain of 28 %, attributed to substitutional solution strengthening and reduced dislocation density. This study not only proposes a strategy for achieving multi-material distribution perpendicular to building direction, but also provides new insights and theoretical complements regarding the molten pool behavior in LPBF.
{"title":"Intralayer deposition mechanism of dissimilar materials by multi-material additive manufacturing based on laser powder-bed fusion","authors":"Yasong Shi , Taitong Jin , Jiawei Ding , Yong Wang , Wei Zhang , Yingbo Peng","doi":"10.1016/j.jmatprotec.2025.119163","DOIUrl":"10.1016/j.jmatprotec.2025.119163","url":null,"abstract":"<div><div>The “layer-by-layer” processing nature of laser powder bed fusion (LPBF) presents challenges for the distribution of multi-materials in the horizontal direction, thereby limiting the design flexibility and functionality of multi-material components. In this study, a \"powder + entity\" interfacial processing model was proposed to achieve intralayer deposition of dissimilar materials via LPBF. In the intralayer deposited SS316L/FeCoCrNi high entropy alloy (HEA)-diamond composites dissimilar-material samples, there was no newly formed phase at the interface, which preserved the γ-austenite and HEA face-centered cubic (FCC) structures, with good interfacial metallurgical bonding. Thermal-fluid coupling simulations showed the asymmetric flow of the mixed molten pool caused by the combined effects of thermal/solute-induced Marangoni flow and gravity, influencing the solidification paths on both sides of the interface. SS316L side characterized by directional melt flow exhibited a preferential crystal-grow orientation that transitioned from < 111 > to < 101 > . Conversely, the composites side displayed anisotropic crystal growth with an increasing dislocation density due to local melt reflux. The interfacial bonding performance of the dissimilar-material samples achieved a yield strength of 430 MPa and a fracture strain of 28 %, attributed to substitutional solution strengthening and reduced dislocation density. This study not only proposes a strategy for achieving multi-material distribution perpendicular to building direction, but also provides new insights and theoretical complements regarding the molten pool behavior in LPBF.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119163"},"PeriodicalIF":7.5,"publicationDate":"2025-11-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145690647","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 : 2025-11-26DOI: 10.1016/j.jmatprotec.2025.119160
Fengyang He , Zening Wu , Zhao Zhang , Donghong Ding , Jun Tong , Huijun Li , Zengxi Pan , Lei Yuan
<div><div>As metal additive manufacturing (AM) advances toward intelligent and data-driven paradigms, reliable sensing has become essential for enabling real-time monitoring, process control and decision making. Among various sensing modalities, acoustic sensing offers unique advantages including high temporal resolution, sensitivity to arc dynamics, and low deployment cost, which have resulted in its widespread adoption in industrial applications. However, most existing acoustic-based methods are developed under static or simplified conditions, without accounting for the dynamic structural evolution inherent in metal AM. This often leads to significant performance degradation, especially when applied to large-scale, high-layer components. This study first identifies and investigates a critical but underexplored phenomenon—<em>structure-induced acoustic modulation</em>—in which the progressive accumulation of volume and variation of geometry throughout the build alters the vibration characteristics and acoustic transmission paths, thereby modulating the emitted acoustic signals. Subsequently, the existence of this modulation and its adverse impact on acoustic-based applications are confirmed through controlled experimental validation. To address this challenge, a dedicated framework based on a ConvNeXt-Adapter-Transformer architecture is then proposed to model the temporal evolution of acoustic signals and enable adaptive generalization across varying builds. The framework is evaluated through the fabrication of a 203-layer circular hollow section component as a case study, demonstrating its ability to effectively adapt to long-duration, structure-evolving metal AM processes. Ultimately, building on this result, a practical acoustic-based application—fabrication process tracing—is deployed and integrated with the proposed framework. The integrated system is further validated through the fabrication of a gear shaft component with complex structures, where results show that the integrated system maintains reliable performance under conditions where baseline systems fail. Specifically, the integrated system achieves a 39.3 % improvement in process tracing accuracy compared to the baseline. Overall, this pioneer study presents the first systematic analysis of structure-induced acoustic modulation in metal AM and introduces an adaptive modelling framework to effectively mitigate the adverse effects of this modulation. Beyond the specific case studies, the identification of structure-induced acoustic modulation itself constitutes a generic scientific finding, revealing that acoustic signals in layer-by-layer AM are inherently modulated by structural evolution. The proposed ConvNeXt-Adapter-Transformer framework further provides a transferable modelling strategy with strong potential for broad adoption in acoustic signal-based applications across the metal AM domain and beyond, enabling reliable performance throughout the manufacturing process and enhan
{"title":"Investigation of the mechanisms of structure-induced acoustic modulation in WA-DED metal additive manufacturing with an adaptive modelling approach","authors":"Fengyang He , Zening Wu , Zhao Zhang , Donghong Ding , Jun Tong , Huijun Li , Zengxi Pan , Lei Yuan","doi":"10.1016/j.jmatprotec.2025.119160","DOIUrl":"10.1016/j.jmatprotec.2025.119160","url":null,"abstract":"<div><div>As metal additive manufacturing (AM) advances toward intelligent and data-driven paradigms, reliable sensing has become essential for enabling real-time monitoring, process control and decision making. Among various sensing modalities, acoustic sensing offers unique advantages including high temporal resolution, sensitivity to arc dynamics, and low deployment cost, which have resulted in its widespread adoption in industrial applications. However, most existing acoustic-based methods are developed under static or simplified conditions, without accounting for the dynamic structural evolution inherent in metal AM. This often leads to significant performance degradation, especially when applied to large-scale, high-layer components. This study first identifies and investigates a critical but underexplored phenomenon—<em>structure-induced acoustic modulation</em>—in which the progressive accumulation of volume and variation of geometry throughout the build alters the vibration characteristics and acoustic transmission paths, thereby modulating the emitted acoustic signals. Subsequently, the existence of this modulation and its adverse impact on acoustic-based applications are confirmed through controlled experimental validation. To address this challenge, a dedicated framework based on a ConvNeXt-Adapter-Transformer architecture is then proposed to model the temporal evolution of acoustic signals and enable adaptive generalization across varying builds. The framework is evaluated through the fabrication of a 203-layer circular hollow section component as a case study, demonstrating its ability to effectively adapt to long-duration, structure-evolving metal AM processes. Ultimately, building on this result, a practical acoustic-based application—fabrication process tracing—is deployed and integrated with the proposed framework. The integrated system is further validated through the fabrication of a gear shaft component with complex structures, where results show that the integrated system maintains reliable performance under conditions where baseline systems fail. Specifically, the integrated system achieves a 39.3 % improvement in process tracing accuracy compared to the baseline. Overall, this pioneer study presents the first systematic analysis of structure-induced acoustic modulation in metal AM and introduces an adaptive modelling framework to effectively mitigate the adverse effects of this modulation. Beyond the specific case studies, the identification of structure-induced acoustic modulation itself constitutes a generic scientific finding, revealing that acoustic signals in layer-by-layer AM are inherently modulated by structural evolution. The proposed ConvNeXt-Adapter-Transformer framework further provides a transferable modelling strategy with strong potential for broad adoption in acoustic signal-based applications across the metal AM domain and beyond, enabling reliable performance throughout the manufacturing process and enhan","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119160"},"PeriodicalIF":7.5,"publicationDate":"2025-11-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145690646","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 : 2025-11-26DOI: 10.1016/j.jmatprotec.2025.119162
Dongyuan Liu, Xiaoyu Cai, Bolun Dong, Sanbao Lin
The complex composition and inherent defects in 7075 aluminum alloys (AA7075) make them prone to grain coarsening and high porosity under wire-arc directed energy deposition using arc (DED-A), leading to inferior mechanical properties in the as-deposited AA7075. To address these issues, this study employs an ultrasonic-frequency pulsed (UFP) variable-polarity tungsten–inert-gas arc process, utilizing specific ultrasonic frequencies of 20, 30, and 40 kHz, for the DED-A of AA7075. A comprehensive comparative investigation is conducted on the microstructure, defects, and mechanical properties of as-deposited AA7075 to elucidate the effects of the UFP arc on DED-A–processed as-deposited AA7075. By utilizing UFP current to excite ultrasonic vibrations, the associated cavitation and acoustic-streaming effects are leveraged to fundamentally alter the solidification dynamics of the melt pool. This process effectively achieves grain refinement and porosity reduction, thereby significantly enhancing the mechanical properties. The results demonstrate that the 30 kHz UFP arc provides optimal microstructural control and performance enhancement for the as-built AA7075, by refining the grain size from 58.86 (non-pulsed) to 50.96 μm, reducing the secondary-phase volume fraction from 9.5 % to 3.63 %, and decreasing the porosity from 1.03 % to 0.38 %. Consequently, the mechanical properties are substantially enhanced. This work proposes a straightforward, yet effective, process for regulating the microstructure and properties of the as-deposited AA7075 prepared via wire-arc DED-A, namely, UFP arc application, which holds significant potential for advancing the DED-A of AA7075 toward aerospace-grade applications.
{"title":"Improving microstructure and mechanical properties of 7075 aluminum alloys prepared via wire-arc directed energy deposition using ultrasonic-frequency pulsed arc","authors":"Dongyuan Liu, Xiaoyu Cai, Bolun Dong, Sanbao Lin","doi":"10.1016/j.jmatprotec.2025.119162","DOIUrl":"10.1016/j.jmatprotec.2025.119162","url":null,"abstract":"<div><div>The complex composition and inherent defects in 7075 aluminum alloys (AA7075) make them prone to grain coarsening and high porosity under wire-arc directed energy deposition using arc (DED-A), leading to inferior mechanical properties in the as-deposited AA7075. To address these issues, this study employs an ultrasonic-frequency pulsed (UFP) variable-polarity tungsten–inert-gas arc process, utilizing specific ultrasonic frequencies of 20, 30, and 40 kHz, for the DED-A of AA7075. A comprehensive comparative investigation is conducted on the microstructure, defects, and mechanical properties of as-deposited AA7075 to elucidate the effects of the UFP arc on DED-A–processed as-deposited AA7075. By utilizing UFP current to excite ultrasonic vibrations, the associated cavitation and acoustic-streaming effects are leveraged to fundamentally alter the solidification dynamics of the melt pool. This process effectively achieves grain refinement and porosity reduction, thereby significantly enhancing the mechanical properties. The results demonstrate that the 30 kHz UFP arc provides optimal microstructural control and performance enhancement for the as-built AA7075, by refining the grain size from 58.86 (non-pulsed) to 50.96 μm, reducing the secondary-phase volume fraction from 9.5 % to 3.63 %, and decreasing the porosity from 1.03 % to 0.38 %. Consequently, the mechanical properties are substantially enhanced. This work proposes a straightforward, yet effective, process for regulating the microstructure and properties of the as-deposited AA7075 prepared via wire-arc DED-A, namely, UFP arc application, which holds significant potential for advancing the DED-A of AA7075 toward aerospace-grade applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119162"},"PeriodicalIF":7.5,"publicationDate":"2025-11-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145621000","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 : 2025-11-23DOI: 10.1016/j.jmatprotec.2025.119161
Dragos Axinte
{"title":"Guidance for authors on contributions the JMPT considers out of scope","authors":"Dragos Axinte","doi":"10.1016/j.jmatprotec.2025.119161","DOIUrl":"10.1016/j.jmatprotec.2025.119161","url":null,"abstract":"","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"347 ","pages":"Article 119161"},"PeriodicalIF":7.5,"publicationDate":"2025-11-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145747106","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}
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