Pub Date : 2024-10-15DOI: 10.1016/j.jmatprotec.2024.118637
Guangyi Zhang , Jiayu Wang , Zhongan Chen , Yaowen Wu , Binying Bao , Wenwu Zhang
Waterjet-guided laser (WGL) processing technology has the advantages of low thermal damage, no contact stress and ultra-fine processing. However, the energy distribution of the existing technology in the laminar flow water column is still characterized by Gaussian distribution, which leads to taper effect in the processing of thick plate materials and affects the deep-processing capability. To address these shortcomings, a novel waterjet laser-field regulation (WLR) method is proposed in this paper. Optical simulation and coupling experiments confirm the method's ability to modulate the energy within the waterjet into a circular distribution, which solves the problem of low power density near the surface of the waterjet. Waterjet-guided laser cutting experiments were conducted based on the WLR method, and the taper was significantly reduced compared to the conventional WGL. At a power of 12 W, the taper was reduced from 5.85° to 2.28°, a reduction of 61 %. In terms of processing depth, the WLR method cuts slightly lower groove depths with a low number of cuts, but as the number of cuts increases, the groove depth steadily increases and exceeds that of the conventional WGL. At 500 cuts with a laser power of 20 W, the groove depths obtained by the WLR method increased by 115 % compared to that of the conventional WGL. This study has important implications for the processing of thick materials by waterjet-guided laser.
{"title":"An optical field regulation method for waterjet-guided laser: Reducing taper and improving deep-processing capability","authors":"Guangyi Zhang , Jiayu Wang , Zhongan Chen , Yaowen Wu , Binying Bao , Wenwu Zhang","doi":"10.1016/j.jmatprotec.2024.118637","DOIUrl":"10.1016/j.jmatprotec.2024.118637","url":null,"abstract":"<div><div>Waterjet-guided laser (WGL) processing technology has the advantages of low thermal damage, no contact stress and ultra-fine processing. However, the energy distribution of the existing technology in the laminar flow water column is still characterized by Gaussian distribution, which leads to taper effect in the processing of thick plate materials and affects the deep-processing capability. To address these shortcomings, a novel waterjet laser-field regulation (WLR) method is proposed in this paper. Optical simulation and coupling experiments confirm the method's ability to modulate the energy within the waterjet into a circular distribution, which solves the problem of low power density near the surface of the waterjet. Waterjet-guided laser cutting experiments were conducted based on the WLR method, and the taper was significantly reduced compared to the conventional WGL. At a power of 12 W, the taper was reduced from 5.85° to 2.28°, a reduction of 61 %. In terms of processing depth, the WLR method cuts slightly lower groove depths with a low number of cuts, but as the number of cuts increases, the groove depth steadily increases and exceeds that of the conventional WGL. At 500 cuts with a laser power of 20 W, the groove depths obtained by the WLR method increased by 115 % compared to that of the conventional WGL. This study has important implications for the processing of thick materials by waterjet-guided laser.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"334 ","pages":"Article 118637"},"PeriodicalIF":6.7,"publicationDate":"2024-10-15","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142442593","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 : 2024-10-12DOI: 10.1016/j.jmatprotec.2024.118634
Jianxing Zhao , Chaowei Zeng , Ting Yuan , Wenyu Du , Yujiang Liu , Yan Wang , Hongjun Hu , Zhuoran Zeng
AZ31 magnesium (Mg) alloy prepared via the extrusion process forms an immensely strong {0001} basal texture, therefore there is a necessity to improve the existing extrusion process to achieve a weakening of the {0001} basal texture of the AZ31 Mg alloy. In this study, a novel process called UVaTESE is proposed. The Mg alloy texture and slip system activation at four ultrasonic vibration (UV) frequencies have been simulated via ABAQUS-VUMAT and VPSC, individually. The simulation results indicate that UV is capable of diffusing the {0001} basal texture of the Mg alloy along the extrusion direction (ED) and transverse direction (TD) and significantly improves the activation of pyramidal slip <c+a>. The simulations are verified experimentally, and the {0001} basal texture of AZ31 Mg alloy has the identical tendency to disperse along ED and TD. Prismatic slip <a> and pyramidal slip <c+a> jointly lead to diffusion of the grain basal texture along the TD, while grains with basal texture diffused along the ED are controlled by both basal slip <a> and pyramidal slip <c+a>. UV has a positive effect on the grain refinement as well as on the homogeneity of AZ31 Mg alloy. The proportion of dynamic recrystallization (DRX) of AZ31 Mg alloy is proportional to the frequency of UV, and it is noteworthy that the mechanism of DRX behavior is not affected by UV. This novel process provides a fundamentally innovative approach to the preparation of Mg alloys and magnesium-aluminum (Mg-Al) composite tubes via extrusion.
{"title":"Ultrasonic vibration-assisted tube extrusion shear expansion (UVaTESE): A novel process to manipulate the texture of AZ31 magnesium alloy","authors":"Jianxing Zhao , Chaowei Zeng , Ting Yuan , Wenyu Du , Yujiang Liu , Yan Wang , Hongjun Hu , Zhuoran Zeng","doi":"10.1016/j.jmatprotec.2024.118634","DOIUrl":"10.1016/j.jmatprotec.2024.118634","url":null,"abstract":"<div><div>AZ31 magnesium (Mg) alloy prepared via the extrusion process forms an immensely strong {0001} basal texture, therefore there is a necessity to improve the existing extrusion process to achieve a weakening of the {0001} basal texture of the AZ31 Mg alloy. In this study, a novel process called UVaTESE is proposed. The Mg alloy texture and slip system activation at four ultrasonic vibration (UV) frequencies have been simulated via ABAQUS-VUMAT and VPSC, individually. The simulation results indicate that UV is capable of diffusing the {0001} basal texture of the Mg alloy along the extrusion direction (ED) and transverse direction (TD) and significantly improves the activation of pyramidal slip <c+a>. The simulations are verified experimentally, and the {0001} basal texture of AZ31 Mg alloy has the identical tendency to disperse along ED and TD. Prismatic slip <a> and pyramidal slip <c+a> jointly lead to diffusion of the grain basal texture along the TD, while grains with basal texture diffused along the ED are controlled by both basal slip <a> and pyramidal slip <c+a>. UV has a positive effect on the grain refinement as well as on the homogeneity of AZ31 Mg alloy. The proportion of dynamic recrystallization (DRX) of AZ31 Mg alloy is proportional to the frequency of UV, and it is noteworthy that the mechanism of DRX behavior is not affected by UV. This novel process provides a fundamentally innovative approach to the preparation of Mg alloys and magnesium-aluminum (Mg-Al) composite tubes via extrusion.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"334 ","pages":"Article 118634"},"PeriodicalIF":6.7,"publicationDate":"2024-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142442652","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 : 2024-10-11DOI: 10.1016/j.jmatprotec.2024.118633
Zejin Zhan , Zhixian Chen , Junqi Zhang , Yi Zhang , Xingzhan Li , Qian Wang , Hui Deng
Precision optical components have stringent requirements on surface roughness, form error, and subsurface damage for superior performance. However, conventional grinding, lapping, and polishing processes of fused silica inevitably introduce subsurface damage (SSD) due to the use of abrasives. Thus, this paper proposes an abrasive-free, low-damage manufacturing process for fused silica optical components, which combines inductively coupled plasma (ICP) for SSD recovery and capacitively coupled plasma (CCP) for form error correction. This paper mainly aims to reveal the advantages and challenges of the combined plasma process. The SSD recovery capability of ICP finishing was first verified. The comparison of surface morphology after buffered oxide etch (BOE) etching and CCP etching revealed that extensive surface roughening is caused by plasma etching rather than SSD. Experimental studies on the combination of ICP and CCP demonstrated that ICP finishing can not only recover SSD but also inhibit the surface roughening by plasma etching. The investigation of form error after ICP finishing revealed that the induced form error consists of workpiece distortion and localized deformation with a crater-like structure, affecting the precision and duration of CCP figuring. The combined plasma process was conducted and a low-damage surface with roughness less than Sa 0.3 nm and form error less than RMS 20 nm was achieved.
{"title":"Low-damage optical manufacturing via plasma finishing and figuring","authors":"Zejin Zhan , Zhixian Chen , Junqi Zhang , Yi Zhang , Xingzhan Li , Qian Wang , Hui Deng","doi":"10.1016/j.jmatprotec.2024.118633","DOIUrl":"10.1016/j.jmatprotec.2024.118633","url":null,"abstract":"<div><div>Precision optical components have stringent requirements on surface roughness, form error, and subsurface damage for superior performance. However, conventional grinding, lapping, and polishing processes of fused silica inevitably introduce subsurface damage (SSD) due to the use of abrasives. Thus, this paper proposes an abrasive-free, low-damage manufacturing process for fused silica optical components, which combines inductively coupled plasma (ICP) for SSD recovery and capacitively coupled plasma (CCP) for form error correction. This paper mainly aims to reveal the advantages and challenges of the combined plasma process. The SSD recovery capability of ICP finishing was first verified. The comparison of surface morphology after buffered oxide etch (BOE) etching and CCP etching revealed that extensive surface roughening is caused by plasma etching rather than SSD. Experimental studies on the combination of ICP and CCP demonstrated that ICP finishing can not only recover SSD but also inhibit the surface roughening by plasma etching. The investigation of form error after ICP finishing revealed that the induced form error consists of workpiece distortion and localized deformation with a crater-like structure, affecting the precision and duration of CCP figuring. The combined plasma process was conducted and a low-damage surface with roughness less than Sa 0.3 nm and form error less than RMS 20 nm was achieved.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"334 ","pages":"Article 118633"},"PeriodicalIF":6.7,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142442651","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 : 2024-10-11DOI: 10.1016/j.jmatprotec.2024.118635
Long Geng , Fan Wu , Mingji Dang , Zhe Feng , Yijie Peng , Chennuo Kang , Wei Fan , Yongxia Wang , Hua Tan , Fengying Zhang , Xin Lin
Recently, laser powder bed fusion (LPBF) of particle-reinforced aluminum matrix composites (PAMCs) with high-strength and high-stiffness have attracted extensive attention in aviation and aerospace. However, performance improvement of single or dual PAMCs using traditional mechanical mixing method is still limited. Therefore, this study innovatively employed pre-alloyed ∼6.5 wt% TiB2/AlSi10Mg composite as the matrix and mechanically mixed SiC particles with different contents (5 vol% and 10 vol%) to fabricate dual PAMCs with high particles content through LPBF. The results indicated that the 5 vol% SiC+TiB2/AlSi10Mg composite revealed relatively weak agglomeration effect of SiC particle and highest relative density (∼99.1 %), thus exhibiting optimal processability. Using this composition material as the research object, it was found that the microstructure maintains the basic features of pre-alloyed TiB2/AlSi10Mg composite except for the slight grain coarsening. However, SiC particles react with α-Al matrix and Al3Ti. Then Al4C3 and TiC enhancement phase were formed, and micron-sized Si particles precipitated within the Al cells surrounded by the eutectic Al-Si. More importantly, due to novel preparation method of dual PAMCs powder, simultaneous enhancement in ultimate tensile strength (∼554.0 MPa), yield strength (∼376.0 MPa), and elastic modulus (∼97.4 GPa) was achieved. Total particle content (∼14.0 wt%) and tensile property were higher than those of reported other PAMCs processed by LPBF. Finally, expect for the fracture characteristics inherent to the pre-alloyed TiB2/AlSi10Mg composite, new fracture mechanism for the tearing of SiC particles was exhibited. This work provides new insights into the preparation of high-strength and high-stiffness PAMCs processed by LPBF.
{"title":"Laser powder bed fusion of SiC particle-reinforced pre-alloyed TiB2/AlSi10Mg composite with high-strength and high-stiffness","authors":"Long Geng , Fan Wu , Mingji Dang , Zhe Feng , Yijie Peng , Chennuo Kang , Wei Fan , Yongxia Wang , Hua Tan , Fengying Zhang , Xin Lin","doi":"10.1016/j.jmatprotec.2024.118635","DOIUrl":"10.1016/j.jmatprotec.2024.118635","url":null,"abstract":"<div><div>Recently, laser powder bed fusion (LPBF) of particle-reinforced aluminum matrix composites (PAMCs) with high-strength and high-stiffness have attracted extensive attention in aviation and aerospace. However, performance improvement of single or dual PAMCs using traditional mechanical mixing method is still limited. Therefore, this study innovatively employed pre-alloyed ∼6.5 wt% TiB<sub>2</sub>/AlSi10Mg composite as the matrix and mechanically mixed SiC particles with different contents (5 vol% and 10 vol%) to fabricate dual PAMCs with high particles content through LPBF. The results indicated that the 5 vol% SiC+TiB<sub>2</sub>/AlSi10Mg composite revealed relatively weak agglomeration effect of SiC particle and highest relative density (∼99.1 %), thus exhibiting optimal processability. Using this composition material as the research object, it was found that the microstructure maintains the basic features of pre-alloyed TiB<sub>2</sub>/AlSi10Mg composite except for the slight grain coarsening. However, SiC particles react with α-Al matrix and Al<sub>3</sub>Ti. Then Al<sub>4</sub>C<sub>3</sub> and TiC enhancement phase were formed, and micron-sized Si particles precipitated within the Al cells surrounded by the eutectic Al-Si. More importantly, due to novel preparation method of dual PAMCs powder, simultaneous enhancement in ultimate tensile strength (∼554.0 MPa), yield strength (∼376.0 MPa), and elastic modulus (∼97.4 GPa) was achieved. Total particle content (∼14.0 wt%) and tensile property were higher than those of reported other PAMCs processed by LPBF. Finally, expect for the fracture characteristics inherent to the pre-alloyed TiB<sub>2</sub>/AlSi10Mg composite, new fracture mechanism for the tearing of SiC particles was exhibited. This work provides new insights into the preparation of high-strength and high-stiffness PAMCs processed by LPBF.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"334 ","pages":"Article 118635"},"PeriodicalIF":6.7,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142535266","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 : 2024-10-11DOI: 10.1016/j.jmatprotec.2024.118636
Li Wang , Hongjie Luo , Shijie Yang , Shibo Cui , Linli Wu
This study introduces an innovative approach to fabricating aluminum foam sandwich with aluminized steel faceplates through metallurgical bonding. The process involves the use of foamable precursor, prepared via melt stirring, and subsequent hot pressing and foaming, offering a cost-effective and industrially feasible method for producing lightweight structural materials and connection of steel/aluminum dissimilar metals. This study focuses on exploring the changes in the microstructure of the bonding interface before and after foaming, and revealing the impact of these changes on the tensile results. Foaming experiment shows that foamable sandwiches have superior foaming ability, and the core layer density after foaming is between 0.283 and 0.591 g/cm ³. Microstructural characterization results demonstrate that, during the hot pressing process, fine equiaxed grains are observed on the iron side of the interface, indicating dynamic recrystallization occurred. The formation of a small amount of η-Al5Fe2 at the interface is a primary factor causing the deflection of the fracture path. Subsequently, during the foaming process, intermetallic compounds (IMCs) θ-Al13Fe4, τ5-Al7Fe2Si, and β-Al4.5FeSi formed sequentially, mainly determined by the diffusion reaction of silicon elements. The formation of these IMCs led to an increase in microhardness at the interface and a decrease in shear strength. Digital image correlation was utilized to examine strain distribution under tensile loading. The result indicates that the damage accumulation is characterized by the formation and expansion of strain bands, with failure manifested as the interconnection of these strain bands.
{"title":"Achieving metallurgical bonding in steel faceplate/aluminum foam sandwich via hot pressing and foaming processes: interfacial microstructure evolution and tensile behavior","authors":"Li Wang , Hongjie Luo , Shijie Yang , Shibo Cui , Linli Wu","doi":"10.1016/j.jmatprotec.2024.118636","DOIUrl":"10.1016/j.jmatprotec.2024.118636","url":null,"abstract":"<div><div>This study introduces an innovative approach to fabricating aluminum foam sandwich with aluminized steel faceplates through metallurgical bonding. The process involves the use of foamable precursor, prepared via melt stirring, and subsequent hot pressing and foaming, offering a cost-effective and industrially feasible method for producing lightweight structural materials and connection of steel/aluminum dissimilar metals. This study focuses on exploring the changes in the microstructure of the bonding interface before and after foaming, and revealing the impact of these changes on the tensile results. Foaming experiment shows that foamable sandwiches have superior foaming ability, and the core layer density after foaming is between 0.283 and 0.591 g/cm ³. Microstructural characterization results demonstrate that, during the hot pressing process, fine equiaxed grains are observed on the iron side of the interface, indicating dynamic recrystallization occurred. The formation of a small amount of η-Al<sub>5</sub>Fe<sub>2</sub> at the interface is a primary factor causing the deflection of the fracture path. Subsequently, during the foaming process, intermetallic compounds (IMCs) θ-Al<sub>13</sub>Fe<sub>4</sub>, τ5-Al<sub>7</sub>Fe<sub>2</sub>Si, and β-Al<sub>4.5</sub>FeSi formed sequentially, mainly determined by the diffusion reaction of silicon elements. The formation of these IMCs led to an increase in microhardness at the interface and a decrease in shear strength. Digital image correlation was utilized to examine strain distribution under tensile loading. The result indicates that the damage accumulation is characterized by the formation and expansion of strain bands, with failure manifested as the interconnection of these strain bands.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"334 ","pages":"Article 118636"},"PeriodicalIF":6.7,"publicationDate":"2024-10-11","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434468","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 : 2024-10-10DOI: 10.1016/j.jmatprotec.2024.118616
Lin Zhu , Huayi Cheng , Kaiming Zhang , Chengcheng Zhang , Changli Liu , Kaishang Li , Shuang Liu , Xiancheng Zhang , Shantung Tu
To obtain thin-walled parts with superior geometric accuracy and fatigue resistance, a novel material surface processing paradigm, double-side simultaneous ultrasonic surface rolling process (DS-USRP), was proposed. The effects of the proposed process on the deformation suppression, surface modification, and fatigue improvement in thin-walled parts of the TA19 titanium alloy were also evaluated in this work. The average geometric deformation of thin-walled parts with the DS-USRP can decrease by ∼30 %. The fatigue life of thin-walled parts at elevated temperatures increased by a maximum of 60.9 times, and the corresponding fatigue strength was increased by 15.43 %. The surface integrity and microstructure of thin-walled parts also significantly change, and there is no failure risk associated with the superimposed effects of bilateral reinforcement. This study demonstrated that the synchronization of the compressive residual stress field evolution on both sides and the temporary increase in static stiffness could suppress the macro-deformation of the thin-walled parts during material surface processing. The improvement in fatigue-resistance at high temperatures is attributed to the low geometrical notch stress concentration and high compressive residual stress field. A moderate rolling intensity is essential to maximize the combined effect of the excellent surface quality and compressive residual stress field. Therefore, the proposed DS-USRP pattern is a promising and effective technique for the high-performance manufacturing of thin-walled parts in titanium alloys.
{"title":"Collaborative improvement of macro-deformation and fatigue property for thin-walled parts in TA19 titanium alloy via a double-sided simultaneous ultrasonic surface rolling process","authors":"Lin Zhu , Huayi Cheng , Kaiming Zhang , Chengcheng Zhang , Changli Liu , Kaishang Li , Shuang Liu , Xiancheng Zhang , Shantung Tu","doi":"10.1016/j.jmatprotec.2024.118616","DOIUrl":"10.1016/j.jmatprotec.2024.118616","url":null,"abstract":"<div><div>To obtain thin-walled parts with superior geometric accuracy and fatigue resistance, a novel material surface processing paradigm, double-side simultaneous ultrasonic surface rolling process (DS-USRP), was proposed. The effects of the proposed process on the deformation suppression, surface modification, and fatigue improvement in thin-walled parts of the TA19 titanium alloy were also evaluated in this work. The average geometric deformation of thin-walled parts with the DS-USRP can decrease by ∼30 %. The fatigue life of thin-walled parts at elevated temperatures increased by a maximum of 60.9 times, and the corresponding fatigue strength was increased by 15.43 %. The surface integrity and microstructure of thin-walled parts also significantly change, and there is no failure risk associated with the superimposed effects of bilateral reinforcement. This study demonstrated that the synchronization of the compressive residual stress field evolution on both sides and the temporary increase in static stiffness could suppress the macro-deformation of the thin-walled parts during material surface processing. The improvement in fatigue-resistance at high temperatures is attributed to the low geometrical notch stress concentration and high compressive residual stress field. A moderate rolling intensity is essential to maximize the combined effect of the excellent surface quality and compressive residual stress field. Therefore, the proposed DS-USRP pattern is a promising and effective technique for the high-performance manufacturing of thin-walled parts in titanium alloys.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"334 ","pages":"Article 118616"},"PeriodicalIF":6.7,"publicationDate":"2024-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142535267","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 : 2024-10-09DOI: 10.1016/j.jmatprotec.2024.118632
Wei Liao, Benle Wang, Zhaoyang Wang, Laihege Jiang, Ming Gao
Oscillating laser-arc hybrid welding (O-LAHW) offers significant advantages in enhancing efficiency and mechanical properties. However, in actual production, gap fluctuations can cause instability, limiting its application in large-scale structure manufacturing. In this study, we explored the impact of gap fluctuation on the destabilization of the molten pool in aluminum alloy O-LAHW and identified the maximum gap tolerance for various conditions. High-speed photography revealed that the oscillating molten pool undergoes a transitional state of periodic collapse before complete instability, a behavior distinct from that of a non-oscillating molten pool. We also analyzed the variations in weld geometry prior to destabilization and developed a global force model of the molten pool to identify key geometrical parameters and related driving forces contributing to destabilization. The results show that maintaining a surface tension ratio of over 55 % at the root of the molten pool is crucial for its stability. Additionally, the effects of oscillatory behavior and gap variations on the laser-substrate interaction were explored, revealing the physical mechanisms behind the changes in key geometrical parameters of the melt pool cross-section. The centrifugal effect generated by high-frequency oscillation is identified as a crucial mechanism for extending the duration of periodic collapse compared to non-oscillating molten pools. By discussing the interactions between energy absorption, molten pool shape, and molten pool forces, the study reveals the evolution process of weld destabilization and explains the differences in gap tolerance between oscillating and non-oscillating laser-arc hybrid welding, providing a reference for improving weld stability.
{"title":"Gap tolerance and molten pool destabilization mechanism in oscillating laser-arc hybrid welding of aluminum alloys","authors":"Wei Liao, Benle Wang, Zhaoyang Wang, Laihege Jiang, Ming Gao","doi":"10.1016/j.jmatprotec.2024.118632","DOIUrl":"10.1016/j.jmatprotec.2024.118632","url":null,"abstract":"<div><div>Oscillating laser-arc hybrid welding (O-LAHW) offers significant advantages in enhancing efficiency and mechanical properties. However, in actual production, gap fluctuations can cause instability, limiting its application in large-scale structure manufacturing. In this study, we explored the impact of gap fluctuation on the destabilization of the molten pool in aluminum alloy O-LAHW and identified the maximum gap tolerance for various conditions. High-speed photography revealed that the oscillating molten pool undergoes a transitional state of periodic collapse before complete instability, a behavior distinct from that of a non-oscillating molten pool. We also analyzed the variations in weld geometry prior to destabilization and developed a global force model of the molten pool to identify key geometrical parameters and related driving forces contributing to destabilization. The results show that maintaining a surface tension ratio of over 55 % at the root of the molten pool is crucial for its stability. Additionally, the effects of oscillatory behavior and gap variations on the laser-substrate interaction were explored, revealing the physical mechanisms behind the changes in key geometrical parameters of the melt pool cross-section. The centrifugal effect generated by high-frequency oscillation is identified as a crucial mechanism for extending the duration of periodic collapse compared to non-oscillating molten pools. By discussing the interactions between energy absorption, molten pool shape, and molten pool forces, the study reveals the evolution process of weld destabilization and explains the differences in gap tolerance between oscillating and non-oscillating laser-arc hybrid welding, providing a reference for improving weld stability.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"334 ","pages":"Article 118632"},"PeriodicalIF":6.7,"publicationDate":"2024-10-09","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142434469","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 : 2024-10-05DOI: 10.1016/j.jmatprotec.2024.118615
Zehao Ning , Huayan Hu , Tianji Zhao , Shujuan Wang , Miao Song
The effort to improve the additive manufacturing (AM) of copper, which is essential in various industrial sectors, has led to the exploration of green laser powder bed fusion (GL-PBF). By using a high-energy green laser, we overcome the challenges posed by the high reflectivity of copper, which has previously hindered achieving the desired component densities and functionalities through AM. This study uncovers the key role of GL-PBF process parameters on the densification, microstructure, surface roughness, mechanical properties, and electrical conductivity of pure copper parts. Our findings demonstrate that optimizing GL-PBF parameters can achieve copper components with over 99.9 % relative density and 98 % international annealed copper standard (IACS) electrical conductivity. The combination of comprehensive experiments and finite element modeling also reveals how the critical role of defect morphology in affecting electrical conductivity. This work contributes to the broader application of AM technologies, especially for high-reflectivity metals, and also provides new insights into how these defects affect conductivity and should be controlled during the AM process.
铜在各个工业领域都至关重要，为了改进铜的增材制造（AM）技术，我们对绿色激光粉末床熔融技术（GL-PBF）进行了探索。通过使用高能量绿激光，我们克服了铜的高反射率所带来的挑战，而这一挑战曾阻碍了通过 AM 实现所需的元件密度和功能。这项研究揭示了 GL-PBF 工艺参数对纯铜部件的致密化、微观结构、表面粗糙度、机械性能和导电性能的关键作用。我们的研究结果表明，优化 GL-PBF 参数可以获得相对密度超过 99.9% 和导电率达到 98% 的国际退火铜标准 (IACS) 铜部件。综合实验和有限元建模还揭示了缺陷形态在影响导电性方面的关键作用。这项工作有助于 AM 技术的更广泛应用，尤其是高反射率金属的应用，同时也为这些缺陷如何影响导电性以及在 AM 过程中应如何控制提供了新的见解。
{"title":"Enhanced electrical and mechanical properties of additively manufactured pure copper with green laser","authors":"Zehao Ning , Huayan Hu , Tianji Zhao , Shujuan Wang , Miao Song","doi":"10.1016/j.jmatprotec.2024.118615","DOIUrl":"10.1016/j.jmatprotec.2024.118615","url":null,"abstract":"<div><div>The effort to improve the additive manufacturing (AM) of copper, which is essential in various industrial sectors, has led to the exploration of green laser powder bed fusion (GL-PBF). By using a high-energy green laser, we overcome the challenges posed by the high reflectivity of copper, which has previously hindered achieving the desired component densities and functionalities through AM. This study uncovers the key role of GL-PBF process parameters on the densification, microstructure, surface roughness, mechanical properties, and electrical conductivity of pure copper parts. Our findings demonstrate that optimizing GL-PBF parameters can achieve copper components with over 99.9 % relative density and 98 % international annealed copper standard (IACS) electrical conductivity. The combination of comprehensive experiments and finite element modeling also reveals how the critical role of defect morphology in affecting electrical conductivity. This work contributes to the broader application of AM technologies, especially for high-reflectivity metals, and also provides new insights into how these defects affect conductivity and should be controlled during the AM process.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"334 ","pages":"Article 118615"},"PeriodicalIF":6.7,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142418364","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 : 2024-10-05DOI: 10.1016/j.jmatprotec.2024.118622
S. Akbarian , A. Salandari-Rabori , S. Sarafan , P. Wanjara , J. Gholipour , A.R.H. Midawi , E. Biro
The challenge of intermetallic compound (IMC) embrittlement, resulting from thick IMC layers at the braze/substrate interface, and the lack of a clear strategy to manipulate IMC formation, has hindered the development of reliable laser weld brazing (LWB) processes. This study addresses these challenges by introducing a novel approach to IMC manipulation during LWB of thin-gauge Zn-coated steel with Si-bronze filler on a double-flanged lap joint. By shifting IMC formation from the interface towards the interior region of the braze, the research mitigates embrittlement by developing a new IMC category, termed surrounded interface-IMCs (SI-IMCs), distinct from traditional interface-IMCs (I-IMCs). The study proposes a Wire-adjusted heat input strategy to optimize brazing conditions, introducing a relative heat input equation (HIRelative) that correlates with various brazing defects and IMC formation. The generic scientific contribution of this work lies in identifying a critical HIRelative value of 32 J/mm for defect-free brazing, with an additional threshold of 12.44 J/mm above this level to promote a high density of SI-IMCs, occupying up to 38.2 ± 16.9 % of the braze cross-sectional area. These SI-IMCs, characterized by a shell-like Fe-Si layer and a bulky (Fe-rich)-Cu eutectic phase, enhance the mechanical performance of the brazed joints. Furthermore, this study reveals the novel role of Mn segregation in creating diffusion channels for Fe-Si IMC development, advancing the scientific understanding of IMC formation. Visualization through digital image correlation (DIC) during tensile testing showed that increasing the SI-IMC area fraction from 1.2 ± 2.4 % to 38.2 ± 16.9 % resulted in a 14 % increase in tensile peak load and a 350 % increase in ductility. This highlights the critical role of SI-IMCs in improving the strength and ductility of LWB joints, offering a new pathway for enhancing the performance of brazed structures.
{"title":"Tailoring intermetallic compound formation within laser weld brazed joints using a novel heat input approach","authors":"S. Akbarian , A. Salandari-Rabori , S. Sarafan , P. Wanjara , J. Gholipour , A.R.H. Midawi , E. Biro","doi":"10.1016/j.jmatprotec.2024.118622","DOIUrl":"10.1016/j.jmatprotec.2024.118622","url":null,"abstract":"<div><div>The challenge of intermetallic compound (IMC) embrittlement, resulting from thick IMC layers at the braze/substrate interface, and the lack of a clear strategy to manipulate IMC formation, has hindered the development of reliable laser weld brazing (LWB) processes. This study addresses these challenges by introducing a novel approach to IMC manipulation during LWB of thin-gauge Zn-coated steel with Si-bronze filler on a double-flanged lap joint. By shifting IMC formation from the interface towards the interior region of the braze, the research mitigates embrittlement by developing a new IMC category, termed surrounded interface-IMCs (SI-IMCs), distinct from traditional interface-IMCs (I-IMCs). The study proposes a Wire-adjusted heat input strategy to optimize brazing conditions, introducing a relative heat input equation (<em>HI</em><sub><em>Relative</em></sub>) that correlates with various brazing defects and IMC formation. The generic scientific contribution of this work lies in identifying a critical <em>HI</em><sub><em>Relative</em></sub> value of 32 J/mm for defect-free brazing, with an additional threshold of 12.44 J/mm above this level to promote a high density of SI-IMCs, occupying up to 38.2 ± 16.9 % of the braze cross-sectional area. These SI-IMCs, characterized by a shell-like Fe-Si layer and a bulky (Fe-rich)-Cu eutectic phase, enhance the mechanical performance of the brazed joints. Furthermore, this study reveals the novel role of Mn segregation in creating diffusion channels for Fe-Si IMC development, advancing the scientific understanding of IMC formation. Visualization through digital image correlation (DIC) during tensile testing showed that increasing the SI-IMC area fraction from 1.2 ± 2.4 % to 38.2 ± 16.9 % resulted in a 14 % increase in tensile peak load and a 350 % increase in ductility. This highlights the critical role of SI-IMCs in improving the strength and ductility of LWB joints, offering a new pathway for enhancing the performance of brazed structures.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"334 ","pages":"Article 118622"},"PeriodicalIF":6.7,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142418366","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2024-10-05DOI: 10.1016/j.jmatprotec.2024.118621
Ding Zhao , Kaidi Li , Jiangkun Fan , Zhixin Zhang , Zesen Chen , Zhiyong Chen , Bin Tang , Qingjiang Wang , Hongchao Kou , Rui Yang , Jinshan Li
Clarifying the bending deformation behaviour of metal foils is essential for meeting the lightweighting requirements of metal honeycomb structures. This study selected Ti65 alloy specimens with various thicknesses and initial α-phase textures to conduct room-temperature three-point bending experiments. A detailed comparative analysis was performed on the bending deformation behaviour of Ti65 alloy sheets and foils. It reveals that in the foil specimens, the weakening effect of surface layer grains is significant. Under the influence of size effects, the springback angle of Ti65 alloy foils with coarse α-phase grains decreases markedly. Additionally, through various methods, including global Schmid factor analysis, lattice rotation analysis, and crystal plasticity finite element method simulations, the specific relationship between α-phase texture and the bending performance of Ti65 alloy foils was thoroughly investigated. The rolling process influences the bending performance of Ti65 alloy by determining the α-phase texture. Unidirectionally rolled Ti65 alloy products exhibit a transverse α-phase texture, which predisposes them to form transverse texture α-phase macrozones during bending. In contrast, cross-directionally rolled Ti65 alloy foils possess a basal α-phase texture biased toward the transverse direction. This not only helps avoid the formation of macrozones but also ensures coordinated deformation across the foil, resulting in superior bending performance.
{"title":"Bending properties and deformation micromechanisms of near-α titanium alloy sheets/foils considering initial texture characteristics and size effect","authors":"Ding Zhao , Kaidi Li , Jiangkun Fan , Zhixin Zhang , Zesen Chen , Zhiyong Chen , Bin Tang , Qingjiang Wang , Hongchao Kou , Rui Yang , Jinshan Li","doi":"10.1016/j.jmatprotec.2024.118621","DOIUrl":"10.1016/j.jmatprotec.2024.118621","url":null,"abstract":"<div><div>Clarifying the bending deformation behaviour of metal foils is essential for meeting the lightweighting requirements of metal honeycomb structures. This study selected Ti65 alloy specimens with various thicknesses and initial α-phase textures to conduct room-temperature three-point bending experiments. A detailed comparative analysis was performed on the bending deformation behaviour of Ti65 alloy sheets and foils. It reveals that in the foil specimens, the weakening effect of surface layer grains is significant. Under the influence of size effects, the springback angle of Ti65 alloy foils with coarse α-phase grains decreases markedly. Additionally, through various methods, including global Schmid factor analysis, lattice rotation analysis, and crystal plasticity finite element method simulations, the specific relationship between α-phase texture and the bending performance of Ti65 alloy foils was thoroughly investigated. The rolling process influences the bending performance of Ti65 alloy by determining the α-phase texture. Unidirectionally rolled Ti65 alloy products exhibit a transverse α-phase texture, which predisposes them to form transverse texture α-phase macrozones during bending. In contrast, cross-directionally rolled Ti65 alloy foils possess a basal α-phase texture biased toward the transverse direction. This not only helps avoid the formation of macrozones but also ensures coordinated deformation across the foil, resulting in superior bending performance.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"334 ","pages":"Article 118621"},"PeriodicalIF":6.7,"publicationDate":"2024-10-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"142418370","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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