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

Correlation between microstructure and residual stress formation in friction stir welded armor steels characterized by neutron diffraction 用中子衍射表征搅拌摩擦焊接装甲钢的显微组织与残余应力形成的关系

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-05 DOI: 10.1016/j.jmatprotec.2026.119198

Jhoan Guzman , Kaue C. Riffel , Martin McDonnell , Jeffrey Bunn , Andrew Payzant , Doug Kyle , Antonio J. Ramirez

Friction stir welding (FSW) is a solid-state joining process that minimizes the heat-affected zone (HAZ) compared with fusion-based arc welding, making it well suited for joining martensitic armor steels where hardness and ballistic resistance are critical. This study investigates residual stress formation in three defect-free FSW butt-joint configurations relevant to armored-vehicle fabrication: similar rolled homogeneous armor (RHA–RHA, Case 1), similar high-hardness armor (HHA–HHA, Case 2), and dissimilar HHA–RHA (Case 3) joints produced under temperature-controlled conditions (770 °C). Neutron diffraction was employed to quantify the magnitude and spatial distribution of residual stresses in the longitudinal, transverse, and normal directions and to correlate them with weld microstructure and hardness. Tensile residual stresses were concentrated in the softened HAZ, reaching approximately 300 MPa for Case 2 and 400 MPa for Case 1 (≈50–70 % of the base-metal yield strength; ∼581 MPa for RHA and ∼566 MPa for HHA), while compressive residual stresses dominated the stir zone. The spatial extent of tensile stresses scaled with the width of the softened HAZ, which was largest in the dissimilar HHA–RHA joint and smallest in the HHA–HHA joint. Full-width-at-half-maximum (FWHM) analysis revealed low microstrain in overtempered HAZ regions and high microstrain in the stir zone associated with severe plastic deformation and fresh martensite formation. This work demonstrates that residual stress evolution in FSW of martensitic armor steels is governed not primarily by peak temperature or thermal contraction, as inferred from fusion-welding analogies, but by the competition between transformation-induced volumetric expansion and tempering-induced stress relaxation. The relative dominance of these mechanisms is shown to depend on alloy hardenability and local thermal history, leading to more extensive HAZ softening and broader tensile stress regions in the lower-hardenability RHA steel. These findings establish a transferable mechanistic framework for optimizing solid-state joining strategies in high-strength steels and other transformation-hardening alloys beyond armor applications.

搅拌摩擦焊（FSW）是一种固态连接工艺，与基于熔焊的电弧焊相比，它可以最大限度地减少热影响区（HAZ），使其非常适合连接硬度和抗弹道性至关重要的马氏体装甲钢。本研究研究了与装甲车辆制造相关的三种无缺陷FSW对接配置的残余应力形成：在温度控制条件下（770°C）生产的类似轧制均匀装甲（rhaa - rha，案例1）、类似高硬度装甲（HHA-HHA，案例2）和不同的HHA-RHA（案例3）接头。采用中子衍射法定量分析了焊缝纵向、横向和法向残余应力的大小和空间分布，并将其与焊缝显微组织和硬度联系起来。拉伸残余应力集中在软化热区，情况2和情况1分别达到约300 MPa和400 MPa(≈母材屈服强度的50-70 %；RHA和HHA分别为~ 581 MPa和~ 566 MPa)，而残余压应力在搅拌区占主导地位。拉伸应力的空间范围与软化热区宽度成比例，不同类型的ha - rha接头拉伸应力最大，ha - hha接头拉伸应力最小。半最大全宽度（FWHM）分析显示，过热回火热影响区微应变低，搅拌区微应变高，伴有严重的塑性变形和新马氏体形成。这项工作表明，马氏体装甲钢的FSW残余应力演变主要不是由熔焊类比推断的峰值温度或热收缩控制，而是由变形引起的体积膨胀和回火引起的应力松弛之间的竞争决定的。这些机制的相对优势取决于合金的淬透性和局部热历史，导致更广泛的热影响区软化和更宽的拉应力区域在淬透性较低的RHA钢。这些发现为优化高强度钢和其他相变硬化合金的固态连接策略建立了可转移的机制框架。

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引用次数: 0

Role of laser beam shape and energy density in modulating surface quality, porosity, microstructure, and mechanical properties of PBF-LB/M Ti-6Al-4V 激光束形状和能量密度对PBF-LB/M Ti-6Al-4V表面质量、孔隙率、微观结构和力学性能的影响

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-03 DOI: 10.1016/j.jmatprotec.2026.119197

Abid Ullah , Alexander E. Medvedev , Dirk Herzog , Andrey Molotnikov , Tingting Liu , Ingomar Kelbassa , Milan Brandt

Beam shaping has recently gained attention as a means to mitigate the thermal gradients and melt-pool instabilities associated with conventional Gaussian beams in laser powder bed fusion (PBF-LB/M), which often lead to surface roughness, defects, and microstructural inconsistency. This study examines the effects of different beam shapes and volumetric energy densities (VEDs) on the surface quality, porosity, microstructure, and mechanical response of Ti-6Al-4V. Cubic specimens were fabricated on an Aconity MIDI+ system using Gaussian, core-ring, and ring beam profiles over a VED range of 78–341 J/mm³ . The results show that beam shaping with optimized VED reduces porosity, refines microstructure, and enhances mechanical performance. The Gaussian beam performed well at low VEDs (≤130 J/mm³) but exhibited increased surface roughness and keyhole porosity at higher energy inputs (≥150 J/mm³), whereas the ring-based beams initially showed higher porosity at low VEDs but achieved ∼99.97 % relative density and smoother surfaces at higher VEDs. The ring beam promoted stable conduction-mode melting, continuous prior-β grain growth, refined α′ martensitic microstructures, and strong crystallographic texture. From a mechanical perspective, Vickers hardness values (370–400 HV) correlated with the observed microstructural features. In addition, the Gaussian beam exhibited higher indicative strength at low VEDs but deteriorated with increasing energy input, whereas the ring beam showed the opposite trend, reaching an ultimate tensile strength of 1192 MPa and ∼21 % ductility under optimal conditions. Beam behavior was further evaluated using areal energy density (AED) normalized to the melt-pool width, indicating that melt-pool stability and the resulting surface quality, porosity, and microstructural evolution are primarily influenced by the spatial distribution of laser energy rather than nominal energy metrics alone. These findings provide a physical basis for laser beam shaping as an effective approach to broaden the stable processing window and achieve defect-free, texture-controlled Ti-6Al-4V components.

在激光粉末床熔合（PBF-LB/M）中，由于传统高斯光束导致表面粗糙度、缺陷和微观结构不一致，因此光束整形作为一种缓解热梯度和熔池不稳定性的手段受到了人们的关注。本研究考察了不同光束形状和体积能量密度（VEDs）对Ti-6Al-4V表面质量、孔隙率、微观结构和力学响应的影响。在Aconity MIDI+ 系统上，采用高斯光束、芯环光束和环形光束剖面，在78-341 J/mm³ 范围内制备立方试样。结果表明：优化后的VED梁形可以降低孔隙率，改善微观结构，提高力学性能。高斯光束在低VEDs下表现良好（≤130 J/mm³），但在更高的能量输入（≥150 J/mm³）下，表面粗糙度和锁孔孔隙度增加，而环基光束在低VEDs下最初表现出更高的孔隙度，但在更高的VEDs下获得了~ 99.97 %的相对密度和更光滑的表面。环形束促进了稳定的导电模式熔化、连续的-β晶粒生长、细化的α′马氏体组织和强的晶体织构。从力学角度看，维氏硬度值（370-400 HV）与观察到的显微组织特征相关。此外，高斯梁在低VEDs下表现出较高的指示强度，但随着能量输入的增加而恶化，而环梁表现出相反的趋势，在最佳条件下达到1192 MPa的极限抗拉强度和~ 21 %的塑性。利用面能密度（AED）对熔池宽度进行归一化，进一步评估了光束行为，表明熔池稳定性以及由此产生的表面质量、孔隙度和微观结构演变主要受到激光能量空间分布的影响，而不仅仅是标称能量指标。这些发现为激光束整形提供了物理基础，作为扩大稳定加工窗口和实现无缺陷、纹理控制的Ti-6Al-4V组件的有效方法。

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引用次数: 0

The mechanism of double pulsed current on improving microstructure and enhancing corrosion resistance of underwater welded 304 stainless steel 双脉冲电流改善304不锈钢水下焊接组织和提高耐蚀性的机理

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-02 DOI: 10.1016/j.jmatprotec.2026.119196

Haipeng Liao , Peng Chi , Lina You , Jianliang Hu , Liang Cheng , Qin Zhang , Xiangmiao Wu , Lianyong Xu , Zhenmin Wang

To overcome the adverse effects of the uneven composition of the molten pool and the poor growth of columnar crystals caused by rapid cooling underwater during underwater welding on the corrosion performance of underwater welds, this study innovatively proposed a double pulsed current (DPC) waveform modulation technology. The influence of different DPC waveforms on the microstructure evolution and corrosion resistance of local dry underwater welded 304 stainless steel (SUS304) was systematically studied. The results show that DPC induced the periodic oscillation of arc energy distribution, which achieved the stirring effect on the underwater molten pool, thereby refining the grain structure by maximum 54.6 %, increasing the ferrite content by 43.2 % and making it uniformly distributed on the austenite matrix. It promoted the transformation of ferrite morphology from skeleton to lath, and enhanced the uniformity of the molten pool composition. With the decrease of the weak pulse peak current, the stirring effect exhibited a trend of first enhancing and then weakening. The corrosion failure mode of the SUS304 underwater weldment was pitting corrosion. The fine grain structure and higher ferrite content brought by DPC facilitated to form a stable passivation film structure, increasing its thickness by 173.1 %, thereby improving the corrosion resistance of underwater weldment. This work provides a flexible solution and solid foundation for underwater welding quality optimizing of austenitic stainless steel, which promote the application of underwater welding technology in the construction and repair of large underwater structures.

为了克服水下焊接过程中熔池组成不均匀和水下快速冷却导致柱状晶体生长不良对水下焊缝腐蚀性能的不利影响，本研究创新性地提出了双脉冲电流（DPC）波形调制技术。系统研究了不同DPC波形对局部水下干焊304不锈钢（SUS304）显微组织演变及耐蚀性能的影响。结果表明：DPC引起电弧能量分布的周期性振荡，对水下熔池产生搅拌作用，最大细化晶粒组织54.6% %，提高铁素体含量43.2% %，使其均匀分布在奥氏体基体上；促进了铁素体形态由骨架向板条的转变，提高了熔池成分的均匀性。随着弱脉冲峰值电流的减小，搅拌效果呈现先增强后减弱的趋势。SUS304水下焊件的腐蚀失效方式为点蚀。DPC带来的细晶粒组织和较高的铁素体含量有利于形成稳定的钝化膜结构，使其厚度增加173.1 %，从而提高了水下焊件的耐腐蚀性。本工作为奥氏体不锈钢水下焊接质量优化提供了灵活的解决方案和坚实的基础，促进了水下焊接技术在大型水下结构施工和修复中的应用。

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引用次数: 0

High-efficiency submerged air jet chemical mechanical polishing at the atomic and close-to-atomic scale 在原子和近原子尺度上高效的浸没式空气射流化学机械抛光

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-02 DOI: 10.1016/j.jmatprotec.2025.119195

Zili Zhang , Song Yuan , Chi Fai Cheung , Wei Wu , Ze Li , Kangsen Li , Chunjin Wang

Fluid jet polishing (FJP) has demonstrated significant potential for polishing and figuring of surfaces with complex geometries owing to its flexibility and shape-adaptive capacity, particularly in high-precision optical applications such as X-ray reflectors, extreme ultraviolet lithography, and super-resolution imaging. Despite its advantages, FJP faces two major challenges that hinder its large-scale industrial adoption. The first challenge is the trade-off between surface quality and material removal efficiency. FJP relies solely on the mechanical impacts of abrasives for material removal, leaving erosion pits on the polished surface. Consequently, existing techniques struggle to achieve sub-nanometer precision while maintaining efficient material removal rates. The second challenge arises from the brittle fracture of materials during the FJP process, complicating the achievement of ultra-smooth surfaces with minimal subsurface damage. To address these limitations, this study introduces Submerged Air Jet Chemical Mechanical Polishing (SAJCMP). This method incorporates a novel material removal mechanism, referred to as “nano-reactive-abrasive-laden droplet-induced chemical mechanical removal,” which enables atomic and close-to-atomic precision while significantly improving polishing efficiency. The multi-scale material removal mechanism is elucidated through both experimental investigations and molecular dynamics (MD) simulations. Furthermore, the influence of various polishing parameters on the synergistic effects of chemical and mechanical actions is analyzed using computational fluid dynamics (CFD) simulations, complemented by experimental validation. Polishing experiments conducted on structured arrays and curved surfaces demonstrated that SAJCMP significantly enhances surface quality, preserves form accuracy, and minimizes subsurface damage.

流体射流抛光（FJP）由于其灵活性和形状自适应能力，在复杂几何形状表面的抛光和加工方面显示出巨大的潜力，特别是在高精度光学应用中，如x射线反射器、极紫外光刻和超分辨率成像。尽管有其优势，但FJP面临着阻碍其大规模工业应用的两个主要挑战。第一个挑战是表面质量和材料去除效率之间的权衡。FJP仅依靠磨料的机械冲击去除材料，在抛光表面留下侵蚀坑。因此，现有的技术努力达到亚纳米精度，同时保持有效的材料去除率。第二个挑战来自FJP过程中材料的脆性断裂，使实现超光滑表面和最小亚表面损伤变得复杂。为了解决这些局限性，本研究引入了水下喷气化学机械抛光（SAJCMP）。该方法采用了一种新型的材料去除机制，称为“纳米反应-负载磨料的液滴诱导化学机械去除”，可实现原子和接近原子的精度，同时显着提高抛光效率。通过实验研究和分子动力学模拟，阐明了多尺度材料的去除机理。此外，利用计算流体动力学（CFD）模拟分析了不同抛光参数对化学和机械作用协同效应的影响，并辅以实验验证。在结构阵列和曲面上进行的抛光实验表明，SAJCMP可以显著提高表面质量，保持形状精度，并最大限度地减少亚表面损伤。

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引用次数: 0

Corrigendum to "Regulation of PBF-LB/M melt pool oscillation behavior via beam shaping: A study based on time-frequency characteristics of coaxial radiation signals" [J. Mater. Process. Technol. 348 (2026) 119181] “通过光束整形调节PBF-LB/M熔池振荡行为：基于同轴辐射信号时频特性的研究”[J]。板牙。的过程。科技. 348 (2026)119181]

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2026-01-02 DOI: 10.1016/j.jmatprotec.2025.119191

Tao Zhu , Xiangjun Xiang , Qiang Gong , Jiaxing Wen , Lai Wei , Tian Huang , Hongkai Jin , Changqiu Chen , Huabin He , Kaihua Sun , Xianfeng Shen , Shuke Huang

引用次数: 0

Critical wrinkling analysis under bending-torsion coupled of spatial tubes during free bending forming 自由弯曲成形过程中空间管弯曲-扭转耦合下的临界起皱分析

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-12-31 DOI: 10.1016/j.jmatprotec.2025.119192

Hui Wang, Jianjun Wu, Zekun Yang, Long Liu, Mengyuan Wang

Wrinkling instability of spatial tubes caused by inappropriate combinations of process parameters during free bending forming (FBF) severely restricts the forming stability. The correlation mechanism between the critical wrinkling loads (CWL) under bending-torsion coupled and the process window remains unclear, which makes it difficult to effectively control wrinkling defects of spatial tubes FBF. This study establishes a critical wrinkling analysis model under bending-torsion coupled (CWAM-CBT) of spatial tubes to calculate CWL. Based on the energy physical meaning of yielding and combined with the quadratic model of bending-torsion buckling (QM-BTB), approximate upper and lower bounds of buckling strength are proposed as the wrinkling criterion. The effects of load ratio, radius-to-thickness ratio, and tube material properties on the CWL and buckling strength are investigated. The validity of the analysis model is verified through a simplified finite element model. By combining the analysis model with finite element simulation of spatial tubes FBF, the critical wrinkling loading path of spatial tubes is constructed according to the relationship between process parameters and load ratios in the stable forming stage. The critical wrinkling loading path divides the process window into three zones, namely the wrinkling zone, the critical wrinkling zone, and the without wrinkling zone. Experiments on spatial tubes FBF have verified that the critical wrinkling loading path can accurately predict the wrinkling behavior under different process parameters, while further validating the effectiveness of the analytical model. This work enhances the in-depth understanding of the bending-torsion coupled wrinkling mechanism during spatial tubes FBF, thereby providing an effective method for the process optimization of complex spatial tube components.

在自由弯曲成形过程中，由于工艺参数组合不当导致空间管的起皱失稳，严重制约了成形稳定性。弯曲-扭转耦合作用下的临界起皱载荷与工艺窗口之间的相关机制尚不清楚，这给空间管FBF起皱缺陷的有效控制带来了困难。本文建立了弯曲-扭转耦合下空间管的临界起皱分析模型，用于计算空间管的弯曲-扭转耦合下的临界起皱。基于屈服的能量物理意义，结合弯曲-扭转屈曲二次模型（QM-BTB），提出了屈曲强度的近似上下边界作为起皱判据。研究了载荷比、径厚比和管材性能对CWL和屈曲强度的影响。通过简化有限元模型验证了分析模型的有效性。将分析模型与空间管FBF有限元模拟相结合，根据工艺参数与载荷比的关系，构建了空间管稳定成形阶段的临界起皱加载路径。临界起皱加载路径将工艺窗口划分为起皱区、临界起皱区和无起皱区三个区域。空间管FBF实验验证了临界起皱加载路径能够准确预测不同工艺参数下的起皱行为，进一步验证了分析模型的有效性。该工作加深了对空间管FBF弯曲-扭转耦合起皱机理的深入理解，从而为复杂空间管构件的工艺优化提供了有效的方法。

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引用次数: 0

Laser-induced cold metal transfer arc deflection under sidewall constraints: A novel strategy for enhanced sidewall fusion in thick-plate ultra-narrow-gap welding 侧壁约束下激光诱导冷金属转移电弧偏转：一种增强厚板超窄间隙焊接侧壁熔合的新策略

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-12-31 DOI: 10.1016/j.jmatprotec.2025.119194

Xiangchen Fan , Guoliang Qin , Guodong Liang , Huijun Xu , Xueyang Guo

In laser-arc hybrid welding, there is a strong coupling effect between the laser and the arc, which is also known as the laser-induced effect. In our studies, the changes of the cold metal transfer (CMT) arc shape were realized by the laser-induced effect, and the influences of different parameters on this effect were systematically investigated. Our experimental results indicate that wire feeding speed significantly influences welding stability, while laser-arc distance in Y-direction is the key parameter for achieving arc lateral deflection and obtaining induced welds. Within an appropriate laser-arc distance range, the arc can be laser-induced to deflect laterally to one side. So, the deflection phenomenon of the CMT arc can be used in an ultra-narrow-gap (≤ 8 mm) welding process. In this scenario, the CMT arc can deflect towards the sidewall without bending or rotating the welding wire. The laser-induced effect allows the CMT arc to heat the sidewall in conjunction with the laser, thereby achieving sufficient sidewall penetration. High-quality induced welds with sufficient sidewall penetration are obtained within the laser-induced range. Meanwhile, the sidewall space constraints within the narrow-gap grooves enhance the laser-induced range, thereby improving the applicability of this technology. Finally, this technology achieved a 30 mm thick ultra-narrow-gap weld with sufficient sidewall penetration, good formability, and low heat damage. These studies support the research and development of the laser-CMT hybrid ultra-narrow-gap welding process of thick plates in industrial applications.

在激光-电弧复合焊接中，激光与电弧之间存在着强烈的耦合效应，这种耦合效应也被称为激光诱导效应。本研究利用激光诱导效应实现了冷金属转移（CMT）电弧形状的变化，并系统地研究了不同参数对这种影响的影响。实验结果表明，送丝速度对焊接稳定性有显著影响，而y方向激光电弧距离是实现电弧横向偏转和获得感应焊缝的关键参数。在适当的激光电弧距离范围内，激光诱导电弧侧向偏转到一侧。因此，CMT电弧的偏转现象可用于超窄间隙（≤8 mm）焊接工艺。在这种情况下，CMT电弧可以在不弯曲或旋转焊丝的情况下向侧壁偏转。激光诱导效应允许CMT电弧与激光一起加热侧壁，从而实现充分的侧壁穿透。在激光诱导范围内，获得了具有足够侧壁穿透性的高质量诱导焊缝。同时，窄间隙凹槽内的侧壁空间约束增强了激光诱导范围，从而提高了该技术的适用性。最后，该技术实现了30 mm厚的超窄间隙焊缝，具有足够的侧壁穿透性、良好的成形性和低热损伤。这些研究为厚板激光- cmt复合超窄间隙焊接工艺的研究和开发提供了工业应用基础。

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引用次数: 0

Stress-aware graph neural network for springback prediction considering material variations 考虑材料变化的应力感知图神经网络回弹预测

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-12-29 DOI: 10.1016/j.jmatprotec.2025.119189

Hui Wang , Heonyong Lim , Jeong Whan Yoon

Accurate prediction of springback is crucial for quality control in sheet metal forming, especially when available limited data constrains the use of conventional data-driven methods. As the first attempt to apply for Graph Neural Network (GNN) to sheet metal forming process considering material variations, this study newly proposes a graph-based deep learning framework, which leverages Graph Attention Networks to predict nodal coordinates and state variables including stress components, equivalent plastic strain etc. across the part. A two-stage training strategy is introduced to enhance the model’s physical consistency by incorporating stress components as auxiliary targets, while GNN mechanism enables adaptive encoding of material influence on stress distribution. This work advances the fundamental understanding of metal forming by representing the stress–strain–geometry interaction as a spatially connected network, establishing a quantitative link between local mechanical response and global springback behavior. Beyond the case-specific prediction, this study reveals a generic relationship between the spatial evolution of stress–strain fields and the resulting geometric deviation, demonstrating that such physically coupled behavior can be effectively represented through graph topology. This finding provides a generalized framework for modeling deformation–relaxation phenomena in various forming processes. Comparative results show that the proposed framework outperforms a baseline artificial neural network, achieving higher accuracy despite the limited dataset of 256 simulations, and offers strong potential for process optimization and intelligent forming design.

准确的回弹预测对于钣金成形的质量控制至关重要，特别是当可用的有限数据限制了传统数据驱动方法的使用时。作为将图神经网络（GNN）应用于考虑材料变化的钣金成形过程的首次尝试，本研究提出了一种基于图的深度学习框架，该框架利用图注意力网络来预测零件的节点坐标和状态变量，包括应力分量、等效塑性应变等。引入了两阶段训练策略，通过将应力分量作为辅助目标来增强模型的物理一致性，而GNN机制可以自适应编码材料对应力分布的影响。这项工作通过将应力-应变-几何相互作用表示为空间连接网络，在局部机械响应和全局回弹行为之间建立定量联系，从而提高了对金属成形的基本理解。除了个案预测外，本研究还揭示了应力应变场的空间演化与几何偏差之间的一般关系，表明这种物理耦合行为可以通过图拓扑有效地表示。这一发现为模拟各种成形过程中的变形松弛现象提供了一个广义框架。对比结果表明，该框架优于基线人工神经网络，在256个模拟数据有限的情况下仍能获得更高的精度，为工艺优化和智能成形设计提供了强大的潜力。

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引用次数: 0

Laser shock peening of TiC/Inconel 625 composites fabricated via cored wire arc additive manufacturing 芯线电弧增材制造TiC/Inconel 625复合材料的激光冲击强化

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-12-29 DOI: 10.1016/j.jmatprotec.2025.119190

Le Jia , Hao Yi , Huajun Cao , Jun Luo

The increasing demand for high-performance alloys such as Inconel 625 in extreme environments challenges conventional additive manufacturing due to constraints in build size, geometrical accuracy, and mechanical performance. Cored wire arc additive manufacturing provides a promising alternative for fabricating high-performance and multi-material components but suffers from poor surface quality and internal porosity. In this work, laser shock was integrated into the cored wire arc additive manufacturing process to regulate molten pool behavior and enhance layer consolidation. The combined effects of laser shock and torch inclination were systematically investigated. Results indicate that torch inclination promotes droplet transfer and increases energy input, thereby improving deposition stability, with a 45° inclination yielding the optimal morphology. Furthermore, an optimized laser shock peening strategy was established through theoretical analysis, numerical simulation, and experimental validation. Laser shock peening effectively refines the microstructure, enhances TiC-matrix interfacial bonding, and introduces high-density dislocations and twins, collectively reducing defects and improving mechanical and tribological performance at different temperatures. The dominant wear mechanism transitions from severe adhesive and abrasive wear to mild oxidative and micro-abrasive modes, with oxidative wear prevailing at elevated temperatures. Compared with conventional cored wire arc additive manufacturing, the laser shock peening-cored wire arc additive manufacturing hybrid exhibits significant improvements in ultimate tensile strength, yield strength, and elongation by 7.8 %, 10.8 %, and 23.9 %, respectively, demonstrating a synergistic enhancement in both strength and ductility. This work presents an effective approach to regulate forming quality and performance in cored wire arc additive manufacturing, providing insights for advancing wire arc additive manufacturing-based high-performance manufacturing of metal matrix composites.

在极端环境中对高性能合金（如Inconel 625）的需求日益增长，这对传统的增材制造提出了挑战，因为它在尺寸、几何精度和机械性能方面受到限制。芯线电弧增材制造为制造高性能和多材料部件提供了一种有前途的替代方案，但其表面质量差，内部孔隙率低。在这项工作中，将激光冲击集成到芯线电弧增材制造工艺中，以调节熔池行为并增强层固结。系统地研究了激光冲击和火炬倾斜的联合效应。结果表明，火炬倾斜促进液滴转移，增加能量输入，从而提高沉积稳定性，其中45°倾斜产生最佳形貌。通过理论分析、数值模拟和实验验证，建立了优化的激光冲击强化策略。激光冲击强化有效地细化了微观组织，增强了tic基体界面结合，引入了高密度位错和孪晶，共同减少了缺陷，提高了不同温度下的力学和摩擦学性能。主要的磨损机制从严重的粘着磨损和磨粒磨损转变为轻微的氧化磨损和微磨粒磨损，在高温下主要是氧化磨损。与传统的芯线电弧增材制造相比，激光冲击强化-芯线电弧复合增材制造在极限抗拉强度、屈服强度和伸长率方面分别提高了7.8 %、10.8 %和23.9 %，显示出强度和延性的协同增强。本研究提出了一种有效的方法来规范带芯电弧丝增材制造的成形质量和性能，为推进基于电弧丝增材制造的金属基复合材料的高性能制造提供了见解。

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引用次数: 0

Numerical modeling and analysis of stress-induced anisotropic damage and evolution mechanism of YAG single crystals during diamond cutting 金刚石切削过程中YAG单晶应力诱导各向异性损伤的数值模拟与分析及演化机制

IF 7.5 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-12-22 DOI: 10.1016/j.jmatprotec.2025.119186

Shayu Song, Jixiang Ding, Zixuan Chen, Rongtao Shen, Jianguo Zhang, Junfeng Xiao, Jianfeng Xu

Yttrium aluminum garnet (YAG) is widely used in optical systems, yet its anisotropic behavior during ultra-precision diamond cutting remains insufficiently understood. This work investigates the anisotropic damage of (111) YAG during diamond cutting through experiments, numerical simulations, and data-driven analysis. A numerical model incorporating material properties, cutting forces, and stress fields during diamond cutting was established, along with an innovatively proposed stress-driven surface/subsurface deformation model. Minimal damage was observed along the [1−12,-211], and [1−21] directions, while the [1−10,01−1], and [-101] directions showed severe damage, revealing that damage evolves from pits and craters to microcracks and shell fractures, tendentiously aligned with plastic flow and slip directions. TEM validation showed that the least-damaged groove exhibits layered subsurface deformation basically matching numerical predictions, while the most-damaged groove presents crack-like but non-open defects matching cognitive predictions. Combined analysis further revealed that the {220} family of planes constitutes the primary deformation plane in YAG cutting. Ridge-regression analysis quantifies factor contributions, showing that shear modulus dominates the damage level, while stress and Schmid factor exhibit scale-dependent effects. This integrated approach offers both physical insight and quantitative analysis for understanding and optimizing ultra-precision machining of brittle, anisotropic materials.

钇铝石榴石（YAG）广泛应用于光学系统中，但其在超精密金刚石切割中的各向异性行为尚不清楚。本研究通过实验、数值模拟和数据驱动分析研究了金刚石切割过程中（111）YAG的各向异性损伤。建立了包含金刚石切削过程中材料特性、切削力和应力场的数值模型，并创新性地提出了应力驱动的表面/地下变形模型。[1−12，-211]和[1−21]方向损伤最小，而[1−10,01−1]和[-101]方向损伤严重，表明损伤由凹坑和弹坑演变为微裂纹和壳状裂缝，与塑性流动和滑移方向有一定的趋势。TEM验证表明，损伤最小的凹槽呈现分层次地下变形，基本符合数值预测，而损伤最严重的凹槽呈现裂纹状但非开放的缺陷，符合认知预测。综合分析进一步发现，{220}族平面构成YAG切削的主要变形平面。脊回归分析量化了各因素的贡献，表明剪切模量主导了损伤水平，而应力和施密德因子则表现出尺度依赖效应。这种综合方法为理解和优化脆性、各向异性材料的超精密加工提供了物理洞察力和定量分析。

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