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

Bifurcation-dominated nonlinear bending behavior of laser peen forming: Analytical modeling and energy competition mechanism 激光喷孔成形分岔主导的非线性弯曲行为：解析建模和能量竞争机制

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-04-01 Epub Date: 2026-02-06 DOI: 10.1016/j.jmatprotec.2026.119248

Jiancheng Jiang , Yiqiao Song , Siyuan Chen , Yu Wang , Zhi Li , Yongxiang Hu

Surface morphology transitions driven by mismatch strains constitute a fundamental mechanical paradigm ubiquitous in manufacturing processes, such as panel forming. Laser peen forming (LPF) is an innovative and versatile forming process that incrementally shapes metallic panels into various types of surfaces through thousands of laser shocks spot-by-spot. However, the nonlinear bending behavior of LPF remains insufficiently understood. This study reveals that nonlinear deformation in LPF is a bifurcation-dominated nonlinear bending behavior driven by mismatch strain, which is fundamentally influenced by geometric nonlinearity. An analytical model was developed based on equivalent eigenstrain, enabling efficient predictions of nonlinear bending curvatures. Experimental characterization of 2024-T351 aluminum alloy plates across varying dimensions reveals clear bifurcation behavior, where the global morphology transitions from a double-curved to a single-curved configuration as the structure enters the nonlinear regime. Parametric studies using the analytical model provide a comprehensive understanding of the bifurcation behavior, elucidating that the dimensions of the plate significantly affect bifurcation behavior, as confirmed by experimental results. An energy-based analysis of a non-Euclidean plate reveals that bifurcation behavior arises from the competition between stretching and bending energies. An explicit bifurcation criterion is derived for identifying the critical bifurcation point. This work advances the fundamental understanding of mismatch strain-induced morphological transitions and establishes a theoretical framework for the design and stability control of shape morphing structures across different manufacturing processes and applications.

由不匹配应变驱动的表面形态转变构成了在制造过程中普遍存在的基本机械范式，例如面板成形。激光喷丸成形（LPF）是一种创新和通用的成形工艺，通过成千上万的激光冲击，逐点将金属板逐渐成形为各种类型的表面。然而，LPF的非线性弯曲行为仍然没有得到充分的了解。研究表明，LPF的非线性变形是由错配应变驱动的分岔主导的非线性弯曲行为，其本质上受几何非线性的影响。建立了基于等效特征应变的解析模型，实现了非线性弯曲曲率的有效预测。对不同尺寸2024-T351铝合金板的实验表征表明，随着结构进入非线性状态，整体形貌从双曲线转变为单曲线，呈现出明显的分岔行为。使用解析模型的参数化研究提供了对分岔行为的全面理解，阐明了板的尺寸显着影响分岔行为，正如实验结果所证实的那样。基于能量的非欧几里得板的分析表明，分岔行为产生于拉伸和弯曲能量之间的竞争。导出了一个明确的判别关键分岔点的分岔准则。这项工作促进了对错配应变引起的形态转变的基本理解，并为跨不同制造工艺和应用的形状变形结构的设计和稳定性控制建立了理论框架。

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引用次数: 0

Mitigating hydrogen embrittlement in 2205 duplex stainless steel through ultrasonic surface rolling post-treated laser peening 超声波表面轧制后处理激光强化对2205双相不锈钢氢脆的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-29 DOI: 10.1016/j.jmatprotec.2026.119236

Emmanuel Agyenim-Boateng , Shu Huang , Jie Sheng , Yufei Hou , Chaojun Zhao , Qinqing Sha , Jinjin Wen , Shuai Zhang , Yutang Qi , Zhipeng Tan , Mingliang Zhu

Although Laser shock peening (LP) has been used to significantly mitigate hydrogen embrittlement (HE) in alloys, it has been limited by challenges such as a thin layer of relatively discrete surface grains, as well as increased surface roughness, which limits its anti-HE effects. Therefore, ultrasonic surface rolling post-treated laser peening (ULP), which generates a gradient microstructure on the surface of alloys through a combination of ultrasonic surface rolling process (USRP) and LP, was used in this study to improve the hydrogen-induced plasticity loss resistance of 2205 duplex stainless steel. The microstructural evolution, mechanical properties, and resistance to hydrogen-induced plasticity loss of 2205 duplex stainless steel treated by LP, USRP, and ULP were comparatively analyzed. The results show that ULP achieves a significantly higher residual compressive stress than individual LP or USRP treatments. ULP also significantly improves surface roughness, leads to more effective grain refinement with complex grain boundaries, and forms a deeper nanogradient structure on the surface. Additionally, the ULP-induced beneficial microstructural features, such as uniformly distributed high-density dislocations, complex duplex structures, etc., synergistically hinder the migration of hydrogen atoms. This significantly improves the mechanical properties and the hydrogen-induced plasticity loss resistance of 2205 duplex stainless steel. The application of ULP provides new opportunities for expanding the use of surface deformation-strengthening technologies to prevent HE in alloys.

尽管激光冲击强化（LP）已被用于显著减轻合金中的氢脆（HE），但它受到诸如相对离散的表面晶粒薄层以及表面粗糙度增加等挑战的限制，这些挑战限制了其抗氢脆效果。因此，本研究采用超声表面轧制后处理激光强化（ULP），通过超声表面轧制工艺（USRP）和LP相结合，在合金表面产生梯度组织，以提高2205双相不锈钢的抗氢致塑性损失性能。对比分析了LP、USRP和ULP处理2205双相不锈钢的组织演变、力学性能和抗氢致塑性损失性能。结果表明，与单独的LP或USRP处理相比，ULP处理获得了更高的残余压应力。ULP还显著提高了表面粗糙度，在复杂晶界下更有效地细化晶粒，并在表面形成更深的纳米梯度结构。此外，ulp诱导的有利微观结构特征，如均匀分布的高密度位错、复杂的双相结构等，协同阻碍了氢原子的迁移。这显著提高了2205双相不锈钢的力学性能和抗氢致塑性损失性能。ULP的应用为扩大表面变形强化技术的应用提供了新的机会，以防止合金中的HE。

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引用次数: 0

Optimized mechanical properties of AISI 316 stainless steel via robotized ultrasonic multi-needle peening: An experimental and numerical study 通过机器人超声多针强化优化AISI 316不锈钢的力学性能：实验和数值研究

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-02-03 DOI: 10.1016/j.jmatprotec.2026.119242

Adnan Saifan , Bassiouny Saleh , Minghui Hong , Silu Chen

Conventional peening methods often struggle to achieve uniform, controllable strengthening on thin-walled and complex components under combined thermo–mechanical loading. This study develops a robotized ultrasonic multi-needle peening (UMNP) system and a validated experimental–numerical framework for automated process planning and transferable mechanism-based design. The process decouples robotic coverage control (trajectory, speed, step-over) from local impact severity (ultrasonic amplitude, air pressure, stand-off) using a 65-needle array that provides stochastic impacts with spatial averaging. A parameterized multi-needle FE model (ABAQUS/Python), informed by high-speed measurements of needle-tip velocity distributions, predicts plastic indentation and residual-stress profiles with

< 10 %

deviation and is demonstrated on both a thin-walled AISI 316 cylindrical shell (circumferential segmentation with rotary indexing) and a flat plate (raster zig-zag tracks). Two stable regimes (UMNP-2: 21

μ

m; UMNP-3: 35

μ

m amplitude) bound the operating window and establish impact energy density and overlap/coverage as governing design rules. For AISI 316 stainless steel cylindrical shell tested at 10–40 N and 25–300 °C, the high-energy regime produces a 532

μ

m graded hardened layer, increases surface hardness to 410 HV (113%), and introduces peak compressive residual stress of

- 1.1 GPa

with EBSD-confirmed grain refinement to 9

μ

m. A wear-mechanism transition is identified: wear increases at 100 °C due to brittle oxide spallation but decreases at 200–300 °C via a stable Cr₂O₃-rich tribo-oxide, improving wear resistance by 33% at 300 °C (with friction–wear decoupling). The combined automation strategy and validated modeling framework enable scalable surface engineering of thin-walled and non-axisymmetric components for aerospace, energy, and marine applications.

传统的强化方法往往难以实现薄壁和复杂的部件在复合热机械载荷下的均匀、可控强化。本研究开发了一个机器人超声多针强化（UMNP）系统和一个经过验证的实验-数值框架，用于自动化工艺规划和可转移的基于机构的设计。该过程使用65针阵列将机器人覆盖控制（轨迹、速度、跨越）与局部冲击严重程度（超声波振幅、气压、距离）解耦，该阵列提供随机冲击的空间平均。一个参数化的多针有限元模型（ABAQUS/Python），通过对针尖速度分布的高速测量，预测了有10%偏差的塑性压痕和残余应力分布，并在薄壁AISI 316圆柱壳（带旋转分度的圆周分割）和平板（栅格之字形轨迹）上进行了验证。两个稳定区域（UMNP-2: 21 μm； UMNP-3: 35 μm振幅）限定了操作窗口，并建立了冲击能量密度和重叠/覆盖范围作为控制设计规则。在10-40 N和25-300℃条件下，AISI 316不锈钢圆柱壳在高能状态下形成了532 μm的梯度硬化层，表面硬度提高到410 HV(113%)，峰值残余压应力为- 1.1GPa， ebsd证实晶粒细化到9 μm。发现了一种磨损机制转变：在100°C时，由于脆性氧化物剥落，磨损增加，但在200-300°C时，由于富含cr2o3的稳定氧化摩擦，磨损减少，在300°C时，耐磨性提高了33%（摩擦磨损去耦）。结合自动化策略和经过验证的建模框架，可以为航空航天、能源和船舶应用的薄壁和非轴对称组件提供可扩展的表面工程。

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引用次数: 0

Revealing the role of pre-crossed twins assisting recrystallization in deep drawing of AZ31 magnesium alloy sheets 揭示了预交叉孪晶在AZ31镁合金板材拉深成形中促进再结晶的作用

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-29 DOI: 10.1016/j.jmatprotec.2026.119229

Chen Li , Quanxin Shi , Peng Lin , Xinyuan Wu , Hongjie Liu , Wei Liang , Shuyong Jiang

Rolled magnesium alloy sheets often develop a pronounced basal texture, which adversely affects the mechanical properties and formability and thus restricts their potential applications. Therefore, it is of great significance to eliminate the basal texture and thus improve formability of magnesium alloy sheets. A novel texture modification process based on cross compressive restrictive alignment (CCRA) is proposed to activate tensile twins and thus introduce orthogonally distributed textures in AZ31 magnesium alloy. Consequently, CCRA process results in a weakened basal texture where the intensity is reduced from 11 to 2.5 as well as a considerable grain refinement where the grain size is decreased from 10 to 2.22 μm. The presence of (10

\overset{̅}{1}

2) - (01

\overset{̅}{1}

2) twins plays a positive role in improving the basal texture through dynamic recrystallization (DRX). Coupling the Hill48 yield criterion with the Johnson-Cook model, a new model is established to investigate influence of preset twins on deep drawability of magnesium alloy sheets by combining finite element simulation with process experiment. Consequently, preset twins are found to effectively weaken in-plane anisotropy of the sheets. Furthermore, it is found that recrystallization mechanisms for pre-twinned magnesium alloy samples are dominant discontinuous DRX (DDRX) along with continuous DRX (CDRX) and twinning-assisted DRX (TDRX). This study investigates the recrystallization behavior of pre-twinned sheets during hot deformation and develops corresponding finite element models to simulate their forming behavior, successfully filling the research gap concerning the hot deep drawing behavior and recrystallization mechanisms of pre-twinned structures. Meanwhile, the CCRA process is applicable to the secondary processing of large-sized sheets, opening up a new avenue for addressing the anisotropy issue of large-sized magnesium alloy sheets in the industrial sector.

镁合金板材在轧制过程中经常出现明显的基底织构，这对镁合金的机械性能和成形性产生不利影响，从而限制了镁合金板材的潜在应用。因此，消除基体织构，从而提高镁合金板材的成形性具有重要意义。提出了一种基于交叉压缩限制取向（CCRA）的织构改性方法，激活AZ31镁合金的拉伸孪晶，从而引入正交分布织构。因此，CCRA工艺导致基体织构减弱，强度从11 μm降至2.5 μm，晶粒细化程度较高，晶粒尺寸从10 μm降至2.22 μm。（101′2）-（011′2）孪晶的存在对通过动态再结晶（DRX）改善基体织构有积极作用。将Hill48屈服准则与Johnson-Cook模型相结合，采用有限元模拟与工艺试验相结合的方法，建立了预成形孪晶对镁合金板材深拉伸性能影响的新模型。结果表明，预设孪晶可以有效地减弱板材的面内各向异性。此外，还发现预孪晶镁合金样品的再结晶机制主要是不连续DRX (DDRX)，其次是连续DRX （CDRX）和孪生辅助DRX （TDRX）。本研究对预孪晶板在热变形过程中的再结晶行为进行了研究，并建立了相应的有限元模型来模拟其成形行为，成功填补了预孪晶组织热拉深行为和再结晶机理方面的研究空白。同时，CCRA工艺适用于大型镁合金板材的二次加工，为工业领域解决大型镁合金板材的各向异性问题开辟了新的途径。

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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 : 2026-03-01 Epub 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 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 : 2026-03-01 Epub 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

Machine learning aided in situ monitoring of compositional variation during laser additive manufacturing of refractory alloy 机器学习辅助原位监测激光增材制造耐火合金的成分变化

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-10 DOI: 10.1016/j.jmatprotec.2026.119216

Teng Yang , Jitesh Kumar , Yuqi Jin , Brian Squires , Selvamurugan Palaniappan , Jacob Spencer , Sai Kumar Dussa , Zhaochen Gu , Andrey A. Voevodin , Narendra B. Dahotre

<div><div>The present study aimed to conduct <em>in situ</em> composition monitoring during laser-based additive manufacturing of TiZrMoAl<sub>x</sub> refractory complex concentrated alloy (RCCA) using Laser Energy-Assisted Breakdown Spectroscopy (LEABS) system integrated with machine learning (ML). The fs-LEABS system employs an ultra-fast femtosecond pulsed laser (250 fs pulse width, 1 kHz repetition rate) that achieves superior signal-to-noise ratios through athermal ablation mechanisms. This approach yields SNR values of approximately 9 for <em>in situ</em> measurements compared to approximately 5 for conventional <em>ex situ</em> measurements, while minimizing thermal background interference inherent to high-temperature additive manufacturing environments. This in turn assisted in revealing the well-defined characteristic atomic spectral emission lines, which were used for reliable, accurate, real-time quantitative elemental composition analysis. A physics-informed approach based on the ratio of integrated peak areas was combined with ML models to effectively track and interpret composition changes in near real-time. Additionally, a high-speed translation system with high spatial resolution integrated with femtosecond laser energy-assisted breakdown spectroscopy (fs-LEABS) facilitated rapid spatial analysis during AM fabrication involving blended elemental powders with significantly different melting temperatures. During Ti/Zr/Mo/Al RCCA fabrication, Al loss due to vaporization was semi-quantitatively estimated using <em>in situ</em> ML assisted laser energy assisted breakdown spectroscopy analysis. Given that Al has a lower vaporization temperature than Mo, its loss by evaporation was monitored to adjust the Ti/Zr/Mo/Al blend composition accordingly. The proposed system not only provides averaged experimental composition values but also delivers track-by-track, layer-by-layer analysis. This detailed mapping reveals clear vaporization transition behaviors affected by <em>in situ</em> heat accumulation, which align with the behavior predicted by numerical simulations. The Random Forest Regression model achieved R² = 0.95 with mean absolute error of 0.37 at.% and mean absolute percentage error of 5.32 %, successfully predicting aluminum content variations from 4 to 14 at.% in real-time during multi-track, multi-layer fabrication. Validation against Energy Dispersive X-ray Spectroscopy measurements confirmed the system's capability to detect aluminum losses of 3–5 at.% under processing conditions with laser fluence inputs ranging from 120 to 160 J/mm³ . This approach provides a means to monitor and compensate for Al elemental loss, enabling process optimization by tuning the powder composition or adjusting processing parameters to minimize elemental depletion. Although the present work focuses on aluminum vaporization monitoring in TiZrMoAl<sub>x</sub> refractory alloys where elements exhibit significantly different melting and evaporation temp

本研究旨在利用激光能量辅助击破光谱（LEABS）系统与机器学习（ML）相结合，对TiZrMoAlx难熔复合浓缩合金（RCCA）激光增材制造过程中的原位成分进行监测。fs- leabs系统采用超快飞秒脉冲激光器（250 fs脉冲宽度，1 kHz重复频率），通过非热烧蚀机制实现优越的信噪比。该方法的原位测量信噪比约为9，而传统的非原位测量信噪比约为5，同时最大限度地减少了高温增材制造环境固有的热背景干扰。这反过来又有助于揭示明确定义的特征原子光谱发射线，用于可靠、准确、实时的定量元素组成分析。基于综合峰面积比例的物理信息方法与ML模型相结合，可以近实时地有效跟踪和解释成分变化。此外，高空间分辨率的高速平移系统与飞秒激光能量辅助击穿光谱（fs-LEABS）相结合，有助于在AM制造过程中对熔化温度显著不同的混合元素粉末进行快速空间分析。在Ti/Zr/Mo/Al RCCA制备过程中，利用原位ML辅助激光能量辅助击穿光谱分析半定量地估计了由于汽化引起的Al损失。考虑到Al的蒸发温度比Mo低，通过监测Al的蒸发损失来调整Ti/Zr/Mo/Al共混物的组成。所提出的系统不仅提供平均实验成分值，而且提供逐道，逐层分析。这种详细的映射揭示了受原位热积累影响的清晰的汽化转变行为，这与数值模拟预测的行为一致。随机森林回归模型R²= 0.95，平均绝对误差为0.37 at。%，平均绝对百分比误差为5.32 %，成功预测了铝含量在4 ~ 14之间的变化 at。在多轨道，多层制造过程中实时。对能量色散x射线光谱测量的验证证实了该系统能够检测到3-5 at的铝损失。%在激光能量输入范围为120至160 J/mm³ 的加工条件下。这种方法提供了一种监测和补偿铝元素损失的手段，通过调整粉末成分或调整工艺参数来实现工艺优化，以最大限度地减少元素损耗。虽然目前的工作主要集中在元素表现出明显不同的熔化和蒸发温度的TiZrMoAlx耐火合金中的铝蒸发监测，但fs-LEABS-ML方法对基于激光的增材制造中的成分控制挑战具有更广泛的适用性。

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引用次数: 0

Optimizing strength-ductility synergy in dissimilar superalloy joint via low-temperature spark plasma diffusion bonding and post-bonding heat treatment 低温火花等离子扩散焊及焊后热处理优化异种高温合金接头强度-塑性协同效应

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-08 DOI: 10.1016/j.jmatprotec.2026.119210

Weiqi Yang , Yekun Feng , Sujun Liu , Lili Xing , Dongbai Sun , Di Yu , Peng He , Tiesong Lin , Jincheng Lin

Dissimilar joining of GH5188 and GH3536 superalloys faces the long-standing problem of interfacial brittleness and limited ductility. This challenge mainly originates from oxide-film retention, insufficient diffusion, and carbide accumulation at the bonding interface. To resolve these issues, we developed a low-temperature spark plasma diffusion bonding (SPDB) route combined with a post-bond heat treatment, where pulsed-current-induced local heating, oxide-film disruption and short-range mass transport provide clear processing advantages over conventional diffusion bonding. Key experiments demonstrate that a defect-free joint can be produced at 850 °C within only 10 min, forming a straight bonded line containing MnCr₂O₄ spinel, M₂₃C₆ carbides and deformed solid solutions, with a tensile strength of 524 MPa but limited elongation (15.2 %). Subsequent heat treatment at 1100 °C for 1 h triggers interfacial recrystallisation, cross-interface grain growth, and partial dissolution/redistribution of interfacial M₂₃C₆ carbides, transforming the sharp bond line into a recrystallized and compositionally graded diffusion zone. As a result, the joint achieves a strength of 721 MPa and an elongation of 33.8 % at room temperature. At 700 °C, the post-treated joint maintains a strength of 428 MPa and an elongation of 18.2 %, which are 1.75 and 3.37 times higher than those of the as-bonded joint, accompanied by a fracture-mode transition from interfacial cleavage to ductile failure. Overall, this study demonstrates a SPDB + heat treatment strategy capable of overcoming the metallurgical incompatibility of Co-/Ni-based superalloys and achieving a stable strength-ductility synergy at both ambient and elevated temperatures.

GH5188和GH3536高温合金的不同连接方式面临着长期存在的界面脆性和有限延展性问题。这种挑战主要来自于氧化膜的保留、扩散不足和碳化物在键合界面的积聚。为了解决这些问题，我们开发了一种低温火花等离子体扩散键合（SPDB）路线，结合键合后热处理，其中脉冲电流引起的局部加热，氧化膜破坏和短程质量传输提供了比传统扩散键合明显的加工优势。关键实验表明，在850℃温度下，仅需10 min，即可得到无缺陷接头，形成由MnCr₂O₄尖晶石、M₂₃C₆碳化物和变形固溶体组成的直线粘结线，抗拉强度为524 MPa，延伸率有限（15.2 %）。随后在1100°C下进行1 h的热处理，触发界面再结晶、界面间晶粒生长和界面M₂₃C₆碳化物的部分溶解/再分布，将尖锐的结合线转变为再结晶和成分渐变的扩散区。结果表明，该接头的室温强度为721 MPa，伸长率为33.8 %。在700℃时，处理后的接头强度为428 MPa，伸长率为18.2 %，分别是未处理时的1.75倍和3.37倍，并伴随着界面解理向延性破坏的断裂模式转变。总体而言，本研究表明SPDB + 热处理策略能够克服Co-/ ni基高温合金的冶金不相容性，并在室温和高温下实现稳定的强度-塑性协同作用。

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引用次数: 0

Defect formation mechanisms and control strategies for high-performance welding of medium-thick components 中厚构件高性能焊接缺陷形成机理及控制策略

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-03-01 Epub Date: 2026-01-08 DOI: 10.1016/j.jmatprotec.2025.119193

Yue Qiu , Minjie Song , Yilin Wang , Shaoning Geng , Leshi Shu , Wei Wang

High-power laser-arc hybrid welding is a critical technology for achieving single-pass double-sided welding of medium-thick components, while the mechanisms of defect formation and suppression, as well as the microstructural effects on mechanical performance under full penetration, remain unclear. This study integrates extensive welding experiments with an advanced ray-tracing based computational fluid dynamics model to systematically reveal the formation mechanisms and suppression strategies of incomplete penetration, root humping, and upper surface collapse. In addition, electron backscatter diffraction analysis clarifies the microstructural strengthening mechanisms governing weld performance. On this basis, both a wide process window for stable weld formation and a refined window for high-performance welding are established. Experimental results show that laser power and welding velocity mainly affect the morphology of the lower weld surface, whereas wire feeding rate predominantly controls the upper surface. Simulations demonstrate that in the incomplete penetration state, the keyhole–molten pool system exhibits quasi-periodic oscillations, driven by the cyclic expansion and contraction of the keyhole bottom opening, resulting in periodic fluctuations of penetration depth. Root humping and upper surface collapse are primarily caused by the violent keyhole fluctuations at the keyhole bottom. Both experiments and simulations confirm that matching high laser power with high welding velocity and wire feeding rate effectively suppresses these fluctuations, reducing the standard deviation of keyhole area variation from 0.094 mm² to 0.065 mm². Under fully penetrated conditions, a moderate heat input intensifies molten pool convection, which leads to dendrite fragmentation and the formation of new intragranular nucleation sites. This process intensifies the lateral competition growth between grains, promotes grain refinement, increases dislocation density, and elevates the fraction of high-angle grain boundaries. Meanwhile, the enlarged mushy zone and extended solidification time facilitate the δ to γ transformation, collectively improving tensile strength. Accordingly, an optimized and wide process window for well-formed welds is defined by laser power of 10–18 kW, welding velocity of 20–36 mm/s, and wire feeding rate of 233–333 mm/s. Within this window, the high-quality and high-strength process window, defined by a laser power of 15–18 kW, welding velocity of 24–36 mm/s, and wire feeding rate of 233–290 mm/s, enables stable full penetration and defect-free morphology on both sides, achieving single-pass welding of 10 mm-scale medium-thick components.

大功率激光-电弧复合焊接是实现中厚构件单道双面焊接的关键技术，但其缺陷形成和抑制机理以及在全熔透条件下微观组织对力学性能的影响尚不清楚。本研究将大量的焊接实验与先进的基于射线追踪的计算流体动力学模型相结合，系统地揭示了不完全熔透、根部驼峰和上表面塌陷的形成机制和抑制策略。此外，电子背散射衍射分析阐明了影响焊缝性能的微观组织强化机制。在此基础上，建立了稳定焊缝形成的宽工艺窗口和高性能焊接的细化窗口。实验结果表明，激光功率和焊接速度主要影响下焊缝表面的形貌，而送丝速度主要控制上表面的形貌。仿真结果表明，在不完全侵彻状态下，钥匙孔-熔池系统在钥匙孔底开口的循环扩张和收缩的驱动下呈现准周期振荡，导致侵彻深度的周期性波动。根部隆起和上表面塌陷主要是由锁孔底部剧烈的波动引起的。实验和仿真结果均表明，高激光功率与高焊接速度和送丝速率相匹配可以有效抑制这些波动，将锁孔面积变化的标准差从0.094 mm²降低到0.065 mm²。在完全渗透条件下，适度的热输入强化了熔池对流，导致枝晶破碎，形成新的晶内成核位点。这一过程加剧了晶粒间的横向竞争生长，促进了晶粒细化，增加了位错密度，提高了高角度晶界的比例。同时，增大的糊化区和延长的凝固时间有利于合金的δ向γ转变，共同提高了合金的抗拉强度。因此，激光功率为10-18 kW，焊接速度为20-36 mm/s，送丝速度为233-333 mm/s，确定了焊缝成形良好的优化宽工艺窗口。在此窗口内，激光功率为15-18 kW，焊接速度为24-36 mm/s，送丝速度为233-290 mm/s的高质量和高强度工艺窗口，可以实现稳定的全熔透和两侧无缺陷的形貌，实现10 mm级中厚部件的单道焊接。

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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 : 2026-03-01 Epub 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