Pub Date : 2026-03-01Epub Date: 2026-01-28DOI: 10.1016/j.jmatprotec.2026.119230
Wenlong Li , Chuanchuan Jia , Guorui Sun , Qingtai Yao , Ziguo Wang , Chao Chen , Shupeng Wang
The inherent strength-ductility contradiction and pronounced mechanical anisotropy in directed energy deposition (DED) of metallic materials remain a significant scientific challenge. This study proposed a novel hybrid additive manufacturing strategy that decouples material deposition from microstructural refinement by integrating arc-DED with interlayer laser cladding of heterogeneous particles. Using Ti-6Al-4V and SiC as a model system, we demonstrated that this approach enables precise in-situ synthesis of nano-TiC/Ti₅Si₃. A critical finding was the existence of a well-defined threshold (∼1.4 wt% SiC) that triggers a dramatic columnar-to-equiaxed grains transition, refining the α-Ti grain length from 172.4 μm to 22.5 μm. The optimized composite exhibited an exceptional strength-ductility synergy, with an ultimate tensile strength of 1178.4 MPa (+5.1 %) and an elongation of 11.7 % (+44.4 %), while significantly reducing anisotropy from 15.9 % to 10.3 %. This work aimed to establish a versatile and cost-effective processing route that can be extended to other material systems, providing a clear pathway to fabricate large-scale, high-performance, and near-isotropic components via DED.
{"title":"Enhanced strength-ductility synergy in directed energy deposition Ti alloy via interlayer laser cladding heterogeneous particles","authors":"Wenlong Li , Chuanchuan Jia , Guorui Sun , Qingtai Yao , Ziguo Wang , Chao Chen , Shupeng Wang","doi":"10.1016/j.jmatprotec.2026.119230","DOIUrl":"10.1016/j.jmatprotec.2026.119230","url":null,"abstract":"<div><div>The inherent strength-ductility contradiction and pronounced mechanical anisotropy in directed energy deposition (DED) of metallic materials remain a significant scientific challenge. This study proposed a novel hybrid additive manufacturing strategy that decouples material deposition from microstructural refinement by integrating arc-DED with interlayer laser cladding of heterogeneous particles. Using Ti-6Al-4V and SiC as a model system, we demonstrated that this approach enables precise in-situ synthesis of nano-TiC/Ti₅Si₃. A critical finding was the existence of a well-defined threshold (∼1.4 wt% SiC) that triggers a dramatic columnar-to-equiaxed grains transition, refining the α-Ti grain length from 172.4 μm to 22.5 μm. The optimized composite exhibited an exceptional strength-ductility synergy, with an ultimate tensile strength of 1178.4 MPa (+5.1 %) and an elongation of 11.7 % (+44.4 %), while significantly reducing anisotropy from 15.9 % to 10.3 %. This work aimed to establish a versatile and cost-effective processing route that can be extended to other material systems, providing a clear pathway to fabricate large-scale, high-performance, and near-isotropic components via DED.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119230"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185033","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 : 2026-03-01Epub Date: 2026-01-19DOI: 10.1016/j.jmatprotec.2026.119224
Yuhui Xie , Yunfei Meng , Zhichong Li , Yahui Wu , Chao Ge , Yan Liu , Zongtao Zhu , Hui Chen
Weld porosity and joint softening pose significant challenges in laser-arc hybrid welding of thick aluminum alloys. While process optimization and microalloying are known independent remedies, their synergistic coupling mechanism under the non-equilibrium, flow-intensive conditions of laser-arc hybrid welding remains unexplored. This study fundamentally advances the field by revealing how high-frequency beam oscillation interacts with Zr micro-alloying to govern grain refinement and defect suppression. During three-layer laser-arc hybrid welding of 15-mm-thick 6082-T6 alloy, the combined use of laser oscillation and Zr micro-alloying reduced porosity from 8.5 % to near zero and refined the weld grain size by 86.6 % (cap), 93.4 % (filler), and 68.6 % (root). This led to a 30.9 % increase in ultimate tensile strength (to 237 MPa) and a 170 % improvement in elongation, consistently shifting fracture to the heat-affected zone. Mechanistically, the study reveals that oscillation-induced flow fields promote the formation and distribution of both D023-Al3Zr phases and submicron Zr particle clusters. The combined application of TEM analysis and the “edge-to-edge” model indicates that submicron Zr possesses a superior grain-refining efficacy over D023-Al3Zr due to a stronger crystallographic orientation relationship with the α-Al matrix. This work thus establishes a process-metallurgy synergy framework, demonstrating that controlled melt-pool dynamics can actively activate and harness microalloying elements to tailor non-equilibrium solidification structures, a principle applicable beyond the specific alloy studied.
{"title":"Synergistic mechanism of beam oscillation and Zr micro-alloying: Achieving grain refinement and defect suppression in laser-arc hybrid welding of aluminum alloys","authors":"Yuhui Xie , Yunfei Meng , Zhichong Li , Yahui Wu , Chao Ge , Yan Liu , Zongtao Zhu , Hui Chen","doi":"10.1016/j.jmatprotec.2026.119224","DOIUrl":"10.1016/j.jmatprotec.2026.119224","url":null,"abstract":"<div><div>Weld porosity and joint softening pose significant challenges in laser-arc hybrid welding of thick aluminum alloys. While process optimization and microalloying are known independent remedies, their synergistic coupling mechanism under the non-equilibrium, flow-intensive conditions of laser-arc hybrid welding remains unexplored. This study fundamentally advances the field by revealing how high-frequency beam oscillation interacts with Zr micro-alloying to govern grain refinement and defect suppression. During three-layer laser-arc hybrid welding of 15-mm-thick 6082-T6 alloy, the combined use of laser oscillation and Zr micro-alloying reduced porosity from 8.5 % to near zero and refined the weld grain size by 86.6 % (cap), 93.4 % (filler), and 68.6 % (root). This led to a 30.9 % increase in ultimate tensile strength (to 237 MPa) and a 170 % improvement in elongation, consistently shifting fracture to the heat-affected zone. Mechanistically, the study reveals that oscillation-induced flow fields promote the formation and distribution of both D0<sub>23</sub>-Al<sub>3</sub>Zr phases and submicron Zr particle clusters. The combined application of TEM analysis and the “edge-to-edge” model indicates that submicron Zr possesses a superior grain-refining efficacy over D0<sub>23</sub>-Al<sub>3</sub>Zr due to a stronger crystallographic orientation relationship with the α-Al matrix. This work thus establishes a process-metallurgy synergy framework, demonstrating that controlled melt-pool dynamics can actively activate and harness microalloying elements to tailor non-equilibrium solidification structures, a principle applicable beyond the specific alloy studied.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119224"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146034848","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 : 2026-03-01Epub Date: 2026-01-27DOI: 10.1016/j.jmatprotec.2026.119225
Lijuan Zheng , Yongfeng Zhao , Bochun Xu , Xinxiang Li , Yong Sun , Xiangqian Xu , Chengyong Wang
Fabricating high-aspect-ratio microholes in Al₂O₃ ceramics presents a fundamental trade-off: quasi-continuous wave (QCW) laser drilling is efficient but induces severe thermal damage, while femtosecond (fs) laser drilling yields high quality but is limited by a relatively low material removal rate. To address these limitations, this study presents a hybrid laser drilling strategy that integrates quasi-continuous wave (QCW) and femtosecond (Fs) pulse laser irradiation. By coordinating their temporal sequence and exploiting the functional complementarity of the two lasers, the proposed method overcomes the intrinsic constraints of single-laser processing for high-aspect-ratio microhole fabrication. The mechanisms underlying thermally assisted material removal by the QCW laser and cold-precision ablation by the femtosecond laser were examined systematically. The influence of key processing parameters on hole geometry and surface integrity was evaluated, and a process window that balances machining efficiency and form accuracy was established. Under optimized conditions, microholes with a diameter of 175 μm and an aspect ratio of 5.7:1 was produced on 1 mm-thick Al2O3 ceramic substrates. The resulting microholes exhibited high cylindricity, smooth sidewalls, and negligible chipping at both the entrance and exit. This work demonstrates that the sequential QCW-fs hybrid strategy successfully decouples the traditional efficiency-quality trade-off, providing a scalable solution for high-precision microhole fabrication in hard and brittle ceramics.
{"title":"Microhole drilling of Al2O3 ceramic plates through combined quasi-continuous wave and femtosecond pulse laser hybrid process","authors":"Lijuan Zheng , Yongfeng Zhao , Bochun Xu , Xinxiang Li , Yong Sun , Xiangqian Xu , Chengyong Wang","doi":"10.1016/j.jmatprotec.2026.119225","DOIUrl":"10.1016/j.jmatprotec.2026.119225","url":null,"abstract":"<div><div>Fabricating high-aspect-ratio microholes in Al₂O₃ ceramics presents a fundamental trade-off: quasi-continuous wave (QCW) laser drilling is efficient but induces severe thermal damage, while femtosecond (fs) laser drilling yields high quality but is limited by a relatively low material removal rate. To address these limitations, this study presents a hybrid laser drilling strategy that integrates quasi-continuous wave (QCW) and femtosecond (Fs) pulse laser irradiation. By coordinating their temporal sequence and exploiting the functional complementarity of the two lasers, the proposed method overcomes the intrinsic constraints of single-laser processing for high-aspect-ratio microhole fabrication. The mechanisms underlying thermally assisted material removal by the QCW laser and cold-precision ablation by the femtosecond laser were examined systematically. The influence of key processing parameters on hole geometry and surface integrity was evaluated, and a process window that balances machining efficiency and form accuracy was established. Under optimized conditions, microholes with a diameter of 175 μm and an aspect ratio of 5.7:1 was produced on 1 mm-thick Al<sub>2</sub>O<sub>3</sub> ceramic substrates. The resulting microholes exhibited high cylindricity, smooth sidewalls, and negligible chipping at both the entrance and exit. This work demonstrates that the sequential QCW-fs hybrid strategy successfully decouples the traditional efficiency-quality trade-off, providing a scalable solution for high-precision microhole fabrication in hard and brittle ceramics.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119225"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185116","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 : 2026-03-01Epub Date: 2026-01-06DOI: 10.1016/j.jmatprotec.2026.119200
R. Srivastava , B. Venkatesh , S.K. Panigrahi
Miniaturised micro components with high aspect ratios have immense applications in aerospace, biomedical, and micro-electromechanical systems (MEMS). Surface wear and corrosion severely affect the performance of miniaturised components, particularly in their long-term use in reactive or aggressive environmental conditions. Therefore, the manufacturing of high aspect ratio miniaturised components with a protective layer of non-reactive materials is challenging yet has immense utility in the biomedical and MEMS sectors. The present approach aims to provide a consistent and durable coating on the inner periphery of axisymmetric micro components with high aspect ratios. As a case study, the difficult-to-deform Mg (AZ31) alloy has been selected as the primary layer material, which exhibits poor corrosion properties. The primary material, Mg (AZ31), is coated with a corrosion-resistant Al (Al1060) alloy as a secondary layer. The objective of developing layered micro billets to facilitate microextrusion was achieved through an optimised strategy consisting of: (i) Chemical and mechanical treatment, (ii) Severe rolling-based deformation induced processing, and (iii) Micro layered billet extraction. These layered micro billets were subjected to micro backward and micro compound extrusion processes to mass fabricate coated micro cups and micro double cups, respectively, in a single step. Through analysis of manufacturability, mechanical properties, and defect propensity, tests were carried out at temperatures ranging from room temperature (RT) to 400 °C. The diffusional interfacial phase evolution and the role of intermetallic compounds, as well as the dynamic recrystallisation mechanism in achieving an optimum coating, were established through detailed interfacial microstructural and mechanical characterisation. A new innovative manufacturing process for developing coated micro cups and micro double cups has been established.
{"title":"An innovative micro-manufacturing technology for the development of aluminium coated magnesium micro components","authors":"R. Srivastava , B. Venkatesh , S.K. Panigrahi","doi":"10.1016/j.jmatprotec.2026.119200","DOIUrl":"10.1016/j.jmatprotec.2026.119200","url":null,"abstract":"<div><div>Miniaturised micro components with high aspect ratios have immense applications in aerospace, biomedical, and micro-electromechanical systems (MEMS). Surface wear and corrosion severely affect the performance of miniaturised components, particularly in their long-term use in reactive or aggressive environmental conditions. Therefore, the manufacturing of high aspect ratio miniaturised components with a protective layer of non-reactive materials is challenging yet has immense utility in the biomedical and MEMS sectors. The present approach aims to provide a consistent and durable coating on the inner periphery of axisymmetric micro components with high aspect ratios. As a case study, the difficult-to-deform Mg (AZ31) alloy has been selected as the primary layer material, which exhibits poor corrosion properties. The primary material, Mg (AZ31), is coated with a corrosion-resistant Al (Al1060) alloy as a secondary layer. The objective of developing layered micro billets to facilitate microextrusion was achieved through an optimised strategy consisting of: (i) Chemical and mechanical treatment, (ii) Severe rolling-based deformation induced processing, and (iii) Micro layered billet extraction. These layered micro billets were subjected to micro backward and micro compound extrusion processes to mass fabricate coated micro cups and micro double cups, respectively, in a single step. Through analysis of manufacturability, mechanical properties, and defect propensity, tests were carried out at temperatures ranging from room temperature (RT) to 400 °C. The diffusional interfacial phase evolution and the role of intermetallic compounds, as well as the dynamic recrystallisation mechanism in achieving an optimum coating, were established through detailed interfacial microstructural and mechanical characterisation. A new innovative manufacturing process for developing coated micro cups and micro double cups has been established.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119200"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974767","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 : 2026-03-01Epub Date: 2026-01-08DOI: 10.1016/j.jmatprotec.2026.119208
Jinpeng Zhao , Wanfei Ren , Jinkai Xu , Huihui Sun , Haoran Deng , Qingwei Wang
High-precision deep and narrow grooves (DNG) are widely used in the aerospace industry. As one of the effective methods for machining deep and narrow grooves, electrochemical machining (ECM) produces uncontrollable stray corrosion during the machining process, which induces the formation of progressive taper on the sidewalls. This study innovatively proposes an innovative electrochemical machining technology named “Active gas-film insulation method for controllable electrochemical machining”. The movement paths and variation mechanisms of the gas film in the electrolyte environment are analyzed through theoretical analysis and gas-liquid two-phase flow simulation. A gas film electrical signal inversion localization method was designed to assist the experiments, realizing the conversion of the dynamic gas film position into electrical signals and thereby enabling real-time observation of the experimental process. Based on the characterization of the surface quality, contour morphology, and taper measurement of the machined deep and narrow grooves, an in-depth analysis of the formation law of gas film insulation is conducted. It is found that the insulation effect of the gas film exhibits consistent regularity under the optimization of the combined parameters of electrolyte pressure and submerged gas film pressure. Finally, the sidewall taper of the deep and narrow grooves machined by gas film insulation-based electrochemical machining is reduced by approximately 98 % compared with traditional electrochemical machining. To reveal the flexible applicability of gas film insulation, special-shaped deep and narrow groove structures are machined through the dynamic regulation of the insulation area. This study provides a new approach for achieving electrochemical machining of high-precision, controllable complex structures.
{"title":"Active gas-film insulation method for controllable electrochemical machining deep-narrow grooves","authors":"Jinpeng Zhao , Wanfei Ren , Jinkai Xu , Huihui Sun , Haoran Deng , Qingwei Wang","doi":"10.1016/j.jmatprotec.2026.119208","DOIUrl":"10.1016/j.jmatprotec.2026.119208","url":null,"abstract":"<div><div>High-precision deep and narrow grooves (DNG) are widely used in the aerospace industry. As one of the effective methods for machining deep and narrow grooves, electrochemical machining (ECM) produces uncontrollable stray corrosion during the machining process, which induces the formation of progressive taper on the sidewalls. This study innovatively proposes an innovative electrochemical machining technology named “Active gas-film insulation method for controllable electrochemical machining”. The movement paths and variation mechanisms of the gas film in the electrolyte environment are analyzed through theoretical analysis and gas-liquid two-phase flow simulation. A gas film electrical signal inversion localization method was designed to assist the experiments, realizing the conversion of the dynamic gas film position into electrical signals and thereby enabling real-time observation of the experimental process. Based on the characterization of the surface quality, contour morphology, and taper measurement of the machined deep and narrow grooves, an in-depth analysis of the formation law of gas film insulation is conducted. It is found that the insulation effect of the gas film exhibits consistent regularity under the optimization of the combined parameters of electrolyte pressure and submerged gas film pressure. Finally, the sidewall taper of the deep and narrow grooves machined by gas film insulation-based electrochemical machining is reduced by approximately 98 % compared with traditional electrochemical machining. To reveal the flexible applicability of gas film insulation, special-shaped deep and narrow groove structures are machined through the dynamic regulation of the insulation area. This study provides a new approach for achieving electrochemical machining of high-precision, controllable complex structures.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119208"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145974770","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 : 2026-03-01Epub Date: 2026-01-29DOI: 10.1016/j.jmatprotec.2026.119234
Huakai Mao , Long Huang , Zengyan Lv , Tongxin Wang , Haitao Duan , Quanli Luo , Xiang Yao , Nian Liu , Yuqi Peng , Qingsong Mei , Guodong Zhang
TiN-reinforced IN718 composite coatings were prepared using ultrasonic vibration assisted laser directed energy deposition. A new concept of “Seed & Root”-shaped precipitated microstructure was proposed, and the phase composition including Al2O3, TiO2, TiN, MX phase and Laves/γ eutectic phase as well as the morphological evolution law of this microstructure were verified. TiN content and ultrasonic vibration have impacts on the precipitation proportion and uniformity of the precipitated phases. The mechanical properties of the coatings can be regulated by adjusting TiN content, the maximum improvements achieved are 30.9 % in microhardness, 69.7 % in yield strength, and a 47.7 % reduction in wear volume. Due to changes in the morphology and content of the second phase, the wear mechanism of the coatings changes under different TiN addition rates. Ultrasonic vibration exerts a positive effect on the corrosion resistance of the coatings. For coatings with the same TiN addition rate, the corrosion resistance can be enhanced by up to 4.3 times at maximum. The changes in coating properties are mainly reflected in the contributions of solid solution strengthening and second phase strengthening. Ultrasonic vibration promotes solid solution strengthening, while TiN content mainly affects the intensity of second phase strengthening. Ultrasonic waves mainly affect the nucleation rate and molten pool energy through cavitation effect and acoustic streaming effect, thereby regulating the microstructure and properties of the coatings. However, an excessively high TiN addition rate will intensify the attenuation of ultrasonic waves, which in turn has an adverse impact on some properties of the coatings.
{"title":"Microstructure and property regulation of TiN-reinforced IN718 composite coatings via ultrasonic vibration – Manufactured by laser directed energy deposition","authors":"Huakai Mao , Long Huang , Zengyan Lv , Tongxin Wang , Haitao Duan , Quanli Luo , Xiang Yao , Nian Liu , Yuqi Peng , Qingsong Mei , Guodong Zhang","doi":"10.1016/j.jmatprotec.2026.119234","DOIUrl":"10.1016/j.jmatprotec.2026.119234","url":null,"abstract":"<div><div>TiN-reinforced IN718 composite coatings were prepared using ultrasonic vibration assisted laser directed energy deposition. A new concept of “Seed & Root”-shaped precipitated microstructure was proposed, and the phase composition including Al<sub>2</sub>O<sub>3</sub>, TiO<sub>2</sub>, TiN, MX phase and Laves/γ eutectic phase as well as the morphological evolution law of this microstructure were verified. TiN content and ultrasonic vibration have impacts on the precipitation proportion and uniformity of the precipitated phases. The mechanical properties of the coatings can be regulated by adjusting TiN content, the maximum improvements achieved are 30.9 % in microhardness, 69.7 % in yield strength, and a 47.7 % reduction in wear volume. Due to changes in the morphology and content of the second phase, the wear mechanism of the coatings changes under different TiN addition rates. Ultrasonic vibration exerts a positive effect on the corrosion resistance of the coatings. For coatings with the same TiN addition rate, the corrosion resistance can be enhanced by up to 4.3 times at maximum. The changes in coating properties are mainly reflected in the contributions of solid solution strengthening and second phase strengthening. Ultrasonic vibration promotes solid solution strengthening, while TiN content mainly affects the intensity of second phase strengthening. Ultrasonic waves mainly affect the nucleation rate and molten pool energy through cavitation effect and acoustic streaming effect, thereby regulating the microstructure and properties of the coatings. However, an excessively high TiN addition rate will intensify the attenuation of ultrasonic waves, which in turn has an adverse impact on some properties of the coatings.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119234"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146074201","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 : 2026-03-01Epub Date: 2026-02-01DOI: 10.1016/j.jmatprotec.2026.119240
Weiqing Zhang , Zhongze Yang , Yuxuan Liu , He Wu , Weiqiang Zhao , Yu Chen , Debin Shan , Wenchen Xu
During the spinning forming process, modifying the strain path provides a cost-effective method for tailoring the crystallographic texture and the mechanical properties of materials, especially for the metal with hexagonal close-packed (HCP) structure. Notably, the numerous process parameters of multi-pass spinning forming facilitate complex variations with strain paths. The effects of strain path on texture components and strength during the multi-pass spinning forming process were studied. However, the texture evolution mechanism was indeterminate and optimization approach for strain path was necessary to develop. A brand-new 3D boundary condition extracting method, which is capable for clarifying strain diversity of various strain path during the spinning forming, is proposed. The velocity gradients tensor with non-vanishing components captures the deformation characteristic of the spinning forming well. Based on these, a FEM-VPSC-CPFFT computational framework, which is capable of simulating the texture components during multi-pass spinning forming with difference strain path, and quantifying the relative activity frequency of each slip system, is constructed for the first time. The experimental results can further confirm the robustness of this computational framework. The results illustrate that higher relative activity frequencies of prismatic <a> and pyramidal <c + a> slip systems during CS result in more comparatively random textures compared to UDS. The strength enhancing in tangential direction with increasing relative activity frequency of the pyramidal <c + a> slip systems is attributed to the textures formed by the multi-pass CS process.
{"title":"Strain-path-dependent texture evolution and strength enhancement mechanisms of near-alpha titanium alloy during the spinning forming process: Experiments and crystal plasticity simulations","authors":"Weiqing Zhang , Zhongze Yang , Yuxuan Liu , He Wu , Weiqiang Zhao , Yu Chen , Debin Shan , Wenchen Xu","doi":"10.1016/j.jmatprotec.2026.119240","DOIUrl":"10.1016/j.jmatprotec.2026.119240","url":null,"abstract":"<div><div>During the spinning forming process, modifying the strain path provides a cost-effective method for tailoring the crystallographic texture and the mechanical properties of materials, especially for the metal with hexagonal close-packed (HCP) structure. Notably, the numerous process parameters of multi-pass spinning forming facilitate complex variations with strain paths. The effects of strain path on texture components and strength during the multi-pass spinning forming process were studied. However, the texture evolution mechanism was indeterminate and optimization approach for strain path was necessary to develop. A brand-new 3D boundary condition extracting method, which is capable for clarifying strain diversity of various strain path during the spinning forming, is proposed. The velocity gradients tensor with non-vanishing components captures the deformation characteristic of the spinning forming well. Based on these, a FEM-VPSC-CPFFT computational framework, which is capable of simulating the texture components during multi-pass spinning forming with difference strain path, and quantifying the relative activity frequency of each slip system, is constructed for the first time. The experimental results can further confirm the robustness of this computational framework. The results illustrate that higher relative activity frequencies of prismatic <a> and pyramidal <c + a> slip systems during CS result in more comparatively random textures compared to UDS. The strength enhancing in tangential direction with increasing relative activity frequency of the pyramidal <c + a> slip systems is attributed to the textures formed by the multi-pass CS process.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119240"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185032","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 : 2026-03-01Epub Date: 2026-01-19DOI: 10.1016/j.jmatprotec.2026.119223
Jiahui Wang, Lei Wang, Xiu Song, Yang Liu
The precipitate characteristic is crucial for determining the mechanical properties of GH4742 superalloy ingots. A permanent magnetic stirring (PMS) was applied during the solidification of GH4742 superalloy, and the role of PMS on the carbide and γ′ morphologies was studied through combination of the experimental investigation and first-principles calculation. The results show that the aspect ratio of MC carbides decreases by 55.0 % as the PMS rotation speed increases from 0 to 300 rpm, and the morphology transforms from long strip to short strip or block. Those are mainly attributed to 59.6 % decreasing of the constitutional undercooling at the solidification front caused by the fast mass transport with PMS. However, the γ′ phases in the interdendritic region are more significantly influenced by PMS than those in the dendritic core. The γ′ size in the interdendritic region increases by 44.6 % with the increasing PMS rotation speed from 0 to 300 rpm; the γ′ number decreases by 51.1 %; the γ′ morphology transforms from near cuboid to cuboid, cuboid with concave faces and octet. The γ′ morphology transition in the interdendritic region is dominated by the increased γ′-γ lattice misfit by 212.5 %, which is mainly ascribed to that more Ti atoms occupy the Al sites in γ′ phase resulted from the enhanced electron transfer between Ti to Ni atoms by PMS. This study not only offers an effective approach to control the main precipitates in GH4742 superalloy ingots, but also throws light on the effect mechanisms of PMS on the carbide and γ′ morphologies.
{"title":"Role of permanent magnetic stirring on the morphologies of both carbide and γ′ phase in GH4742 superalloy during solidification","authors":"Jiahui Wang, Lei Wang, Xiu Song, Yang Liu","doi":"10.1016/j.jmatprotec.2026.119223","DOIUrl":"10.1016/j.jmatprotec.2026.119223","url":null,"abstract":"<div><div>The precipitate characteristic is crucial for determining the mechanical properties of GH4742 superalloy ingots. A permanent magnetic stirring (PMS) was applied during the solidification of GH4742 superalloy, and the role of PMS on the carbide and γ′ morphologies was studied through combination of the experimental investigation and first-principles calculation. The results show that the aspect ratio of MC carbides decreases by 55.0 % as the PMS rotation speed increases from 0 to 300 rpm, and the morphology transforms from long strip to short strip or block. Those are mainly attributed to 59.6 % decreasing of the constitutional undercooling at the solidification front caused by the fast mass transport with PMS. However, the γ′ phases in the interdendritic region are more significantly influenced by PMS than those in the dendritic core. The γ′ size in the interdendritic region increases by 44.6 % with the increasing PMS rotation speed from 0 to 300 rpm; the γ′ number decreases by 51.1 %; the γ′ morphology transforms from near cuboid to cuboid, cuboid with concave faces and octet. The γ′ morphology transition in the interdendritic region is dominated by the increased γ′-γ lattice misfit by 212.5 %, which is mainly ascribed to that more Ti atoms occupy the Al sites in γ′ phase resulted from the enhanced electron transfer between Ti to Ni atoms by PMS. This study not only offers an effective approach to control the main precipitates in GH4742 superalloy ingots, but also throws light on the effect mechanisms of PMS on the carbide and γ′ morphologies.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119223"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146034899","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 : 2026-03-01Epub Date: 2026-01-29DOI: 10.1016/j.jmatprotec.2026.119233
Zhonghan Yu , Wenjuan Xing , Xianke Li , Changyi Liu , Hongwei Zhao
Optimizing the yield ratio and ductility is essential for improving mechanical adaptability and structural reliability in applications spanning biomedical devices, aerospace structures, and flexible electronics. In this study, AlFeCrNiV high-entropy alloys (HEAs) were fabricated via laser powder bed fusion (LPBF), and the effects of substrate temperature (348 and 573 K) and subsequent aging time (6, 12, 48, and 120 h) on microstructural evolution and tensile properties were systematically investigated. The 348 K-fabricated alloy exhibited finer grains, higher residual stress, and greater dislocation density than that 573 K-fabricated, resulting in higher yield strength (YS=680.2 MPa) and ultimate tensile strength (UTS=902.7 MPa), but lower total elongation to failure (30.5 %). During aging, the 348 K series developed a higher volume fraction of BCC precipitates. After 120 h of aging, the 348 K-fabricated alloy maintained a high UTS (920.8 MPa), while its YS decreased to 474 MPa and elongation increased to 36.2 %, thus achieving a desirable combination of a low yield ratio and improved ductility. In-situ EBSD tensile testing and TEM analysis revealed that finely BCC precipitates act as effective barriers to dislocation motion, promote dislocation storage and multiplication, and significantly improve strain-hardening capability. Additionally, these precipitates induce localized lattice rotation and facilitate the formation of refined subgrain-scale deformation-coordination units, effectively suppressing strain localization. The concurrent reduction in yield ratio and improvement in ductility is thus achieved through the synergistic regulation of dislocation density and BCC precipitation. This study elucidates the intrinsic process–microstructure–property relationships in LPBF-fabricated HEAs and provides a framework for microstructure-driven mechanical optimization.
{"title":"In-situ EBSD investigation of the yield ratio reduction and ductility enhancement mechanisms in laser powder bed fusion Al–Fe–Cr–Ni–V high-entropy alloy","authors":"Zhonghan Yu , Wenjuan Xing , Xianke Li , Changyi Liu , Hongwei Zhao","doi":"10.1016/j.jmatprotec.2026.119233","DOIUrl":"10.1016/j.jmatprotec.2026.119233","url":null,"abstract":"<div><div>Optimizing the yield ratio and ductility is essential for improving mechanical adaptability and structural reliability in applications spanning biomedical devices, aerospace structures, and flexible electronics. In this study, AlFeCrNiV high-entropy alloys (HEAs) were fabricated via laser powder bed fusion (LPBF), and the effects of substrate temperature (348 and 573 K) and subsequent aging time (6, 12, 48, and 120 h) on microstructural evolution and tensile properties were systematically investigated. The 348 K-fabricated alloy exhibited finer grains, higher residual stress, and greater dislocation density than that 573 K-fabricated, resulting in higher yield strength (YS=680.2 MPa) and ultimate tensile strength (UTS=902.7 MPa), but lower total elongation to failure (30.5 %). During aging, the 348 K series developed a higher volume fraction of BCC precipitates. After 120 h of aging, the 348 K-fabricated alloy maintained a high UTS (920.8 MPa), while its YS decreased to 474 MPa and elongation increased to 36.2 %, thus achieving a desirable combination of a low yield ratio and improved ductility. In-situ EBSD tensile testing and TEM analysis revealed that finely BCC precipitates act as effective barriers to dislocation motion, promote dislocation storage and multiplication, and significantly improve strain-hardening capability. Additionally, these precipitates induce localized lattice rotation and facilitate the formation of refined subgrain-scale deformation-coordination units, effectively suppressing strain localization. The concurrent reduction in yield ratio and improvement in ductility is thus achieved through the synergistic regulation of dislocation density and BCC precipitation. This study elucidates the intrinsic process–microstructure–property relationships in LPBF-fabricated HEAs and provides a framework for microstructure-driven mechanical optimization.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119233"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146074288","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 : 2026-03-01Epub Date: 2026-01-29DOI: 10.1016/j.jmatprotec.2026.119231
Yonghua Zhao, Yijin Zhong, Tao Wang, Wenjun Lu
Mechanical methods for thinning and polishing silicon carbide (SiC) semiconductor wafers are often costly and inefficient due to the material’s extreme hardness and chemical inertness. This study explores electrolytic plasma polishing (EPP) as a novel, cost-effective, and damage-free processing route for semiconductor 4H-SiC. Adapting EPP to semiconductors poses distinct scientific and technical challenges compared to traditional metal workpieces due to the substantial differences in material properties. This study investigates the effectiveness of EPP on 4H-SiC and establishes the underlying mechanism. Unlike the anodic dissolution mechanism observed in metal EPP processes, this work provides experimental evidence of a plasma-driven chemical etching mechanism that facilitates efficient removal of 4H-SiC by OH- ions in a 5 wt% NaOH electrolyte. Surface pitting and oxidation govern surface morphology. A maximum etching rate of ∼3 μm/min enables rapid wafer thinning while achieving a mirror-like surface finish with roughness Sa < 12 nm. A rotary EPP process on a 1-inch wafer achieves a total thickness variation of ∼2 μm. Transmission electron microscopy reveals a ∼20 nm oxide layer on the polished surface, with no detectable subsurface damage. These findings extend the applicability of EPP beyond metals and demonstrate its potential as a fast and environmentally sustainable method for processing semiconductor wafers.
{"title":"Electrolytic plasma as a novel route for damage-free polishing and thinning of semiconductor 4H-SiC wafers","authors":"Yonghua Zhao, Yijin Zhong, Tao Wang, Wenjun Lu","doi":"10.1016/j.jmatprotec.2026.119231","DOIUrl":"10.1016/j.jmatprotec.2026.119231","url":null,"abstract":"<div><div>Mechanical methods for thinning and polishing silicon carbide (SiC) semiconductor wafers are often costly and inefficient due to the material’s extreme hardness and chemical inertness. This study explores electrolytic plasma polishing (EPP) as a novel, cost-effective, and damage-free processing route for semiconductor 4H-SiC. Adapting EPP to semiconductors poses distinct scientific and technical challenges compared to traditional metal workpieces due to the substantial differences in material properties. This study investigates the effectiveness of EPP on 4H-SiC and establishes the underlying mechanism. Unlike the anodic dissolution mechanism observed in metal EPP processes, this work provides experimental evidence of a plasma-driven chemical etching mechanism that facilitates efficient removal of 4H-SiC by OH<sup>-</sup> ions in a 5 wt% NaOH electrolyte. Surface pitting and oxidation govern surface morphology. A maximum etching rate of ∼3 μm/min enables rapid wafer thinning while achieving a mirror-like surface finish with roughness Sa < 12 nm. A rotary EPP process on a 1-inch wafer achieves a total thickness variation of ∼2 μm. Transmission electron microscopy reveals a ∼20 nm oxide layer on the polished surface, with no detectable subsurface damage. These findings extend the applicability of EPP beyond metals and demonstrate its potential as a fast and environmentally sustainable method for processing semiconductor wafers.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"349 ","pages":"Article 119231"},"PeriodicalIF":7.5,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185115","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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