Journal of Materials Processing Technology最新文献_第3页

Influence of Electrolyte Pressure on Localised Electrochemical Deposition Quality

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-04-03 DOI: 10.1016/j.jmatprotec.2025.118832

Manfei Wang , Wanfei Ren , Jinkai Xu , Zhaoqiang Zou , Huihui Sun , Ningqian Tang , Zhengyi Yang , Hanhan Wei , Yan Huo

Micro-nanostructures have unique advantages and are widely used in fields such as microelectronics, biomedicine, optical engineering, and renewable energy. However, these fields have extremely strict requirements for the accuracy and performance of micro-nanostructures, and the manufacture of high-quality and high-precision microstructures has become an urgent research problem. This study focuses on the influence of the electrolyte extrusion pressure on the flow rate, current density, and deposition quality. The results indicate that the deposition structure presents a characteristic columnar growth morphology. Within a certain range, a higher extrusion pressure can enhance the quality and precision of the deposition structures. As the extrusion pressure increases, the uniformity of the deposition structure is significantly improved, with a roughness of up to 19.343 nm and a uniformity coefficient α <0.2. In addition, this study establishes a relationship model between the extrusion pressure and deposition diameter, accurately adjusting the deposition diameter within a specific range and overcoming the difficulties of high-precision micro-nanostructure manufacturing. This model provides guidance for electrochemical deposition manufacturing and a solid foundation for further application and development of micro-nanostructures.

{"title":"Influence of Electrolyte Pressure on Localised Electrochemical Deposition Quality","authors":"Manfei Wang , Wanfei Ren , Jinkai Xu , Zhaoqiang Zou , Huihui Sun , Ningqian Tang , Zhengyi Yang , Hanhan Wei , Yan Huo","doi":"10.1016/j.jmatprotec.2025.118832","DOIUrl":"10.1016/j.jmatprotec.2025.118832","url":null,"abstract":"<div><div>Micro-nanostructures have unique advantages and are widely used in fields such as microelectronics, biomedicine, optical engineering, and renewable energy. However, these fields have extremely strict requirements for the accuracy and performance of micro-nanostructures, and the manufacture of high-quality and high-precision microstructures has become an urgent research problem. This study focuses on the influence of the electrolyte extrusion pressure on the flow rate, current density, and deposition quality. The results indicate that the deposition structure presents a characteristic columnar growth morphology. Within a certain range, a higher extrusion pressure can enhance the quality and precision of the deposition structures. As the extrusion pressure increases, the uniformity of the deposition structure is significantly improved, with a roughness of up to 19.343nm and a uniformity coefficient α <0.2. In addition, this study establishes a relationship model between the extrusion pressure and deposition diameter, accurately adjusting the deposition diameter within a specific range and overcoming the difficulties of high-precision micro-nanostructure manufacturing. This model provides guidance for electrochemical deposition manufacturing and a solid foundation for further application and development of micro-nanostructures.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118832"},"PeriodicalIF":6.7,"publicationDate":"2025-04-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143776378","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}

引用次数: 0

Real-time interface monitoring and active focusing for high-fidelity multi-material DLP 3D printing

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-04-03 DOI: 10.1016/j.jmatprotec.2025.118834

Yuhao Guo , Xiangjun Zha , Xinyu Huang , Zhicheng Cheng , Tingxian Ling , Jigang Huang

Top-down digital light processing (DLP) 3D printing is a promising approach for high-resolution and multi-material fabrication. However, the unconstrained resin surface often leads to curing outside the focal plane during the printing process, resulting in significant losses in manufacturing accuracy. To address this defocusing issue, we propose an improved top-down DLP 3D printing method that enables real-time calibration of the resin level, ensuring each layer is printed precisely on the focal plane. This approach reduces the deviation between the curing plane and the focal plane from hundreds of microns to just a few microns, significantly enhancing printing resolution and surface finish. Additionally, the method allows for the fabrication of multi-material objects with gradual interfaces in a single vat, improving bonding strength between different materials. Moreover, by controlling the resin level, the proposed technique facilitates material switching between multiple vats while maintaining a constant curing plane, enabling the creation of high-fidelity multi-material structures. This innovative strategy advances the field of DLP 3D printing by offering a rapid, precise, and versatile solution for high-resolution and multi-material fabrication.

{"title":"Real-time interface monitoring and active focusing for high-fidelity multi-material DLP 3D printing","authors":"Yuhao Guo , Xiangjun Zha , Xinyu Huang , Zhicheng Cheng , Tingxian Ling , Jigang Huang","doi":"10.1016/j.jmatprotec.2025.118834","DOIUrl":"10.1016/j.jmatprotec.2025.118834","url":null,"abstract":"<div><div>Top-down digital light processing (DLP) 3D printing is a promising approach for high-resolution and multi-material fabrication. However, the unconstrained resin surface often leads to curing outside the focal plane during the printing process, resulting in significant losses in manufacturing accuracy. To address this defocusing issue, we propose an improved top-down DLP 3D printing method that enables real-time calibration of the resin level, ensuring each layer is printed precisely on the focal plane. This approach reduces the deviation between the curing plane and the focal plane from hundreds of microns to just a few microns, significantly enhancing printing resolution and surface finish. Additionally, the method allows for the fabrication of multi-material objects with gradual interfaces in a single vat, improving bonding strength between different materials. Moreover, by controlling the resin level, the proposed technique facilitates material switching between multiple vats while maintaining a constant curing plane, enabling the creation of high-fidelity multi-material structures. This innovative strategy advances the field of DLP 3D printing by offering a rapid, precise, and versatile solution for high-resolution and multi-material fabrication.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118834"},"PeriodicalIF":6.7,"publicationDate":"2025-04-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143776379","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}

引用次数: 0

Mechanistic optimization of wide-gap ultrafast laser quartz glass welding with plasma dynamics

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-04-02 DOI: 10.1016/j.jmatprotec.2025.118840

Ning Jiang, Rundong Qian, Huize Yin, Chenyi Ni, Yayun Liu, Haiyu Qiao, Chuanyang Wang

Ultrafast lasers have the advantages of high speed, small heat-affected zones, and non-contact processing. They can achieve fine welding in the field of microelectronic packaging, improve product quality, and reduce losses. However, ultrafast laser glass welding under wide-gap conditions faces challenges such as insufficient filling and an unstable molten pool, which limit its operability in practical applications. In this study the factors influencing welding strength are investigated by studying the interaction mechanism between the laser and glass, plasma density evolution, and temperature field analysis. First, the principle of irreversible expansion occurring in large gaps during welding was analyzed, and the welding results under different conditions were explained according to this principle. Avalanche ionization and photoionization are key mechanisms of plasma-induced irreversible expansion. Second, to obtain the optimal process parameters for use in the experiment, the plasma density and temperature field were numerically simulated, which reduced the experimental group and improved the experimental efficiency. Finally, the relationships between the process parameters, cavity shape, and welding strength were verified in an experiment involving ultrafast laser welding of quartz glass. The revealed plasma–cavity interaction mechanism and predictive modeling framework are applicable to a broad class of transparent dielectrics, offering a transferable scientific basis for precision laser joining. This work provides foundational insights into laser–matter interaction under wide-gap conditions and supports future extensions to heterogeneous material systems, complex interface geometries, and high-integration photonic manufacturing.

{"title":"Mechanistic optimization of wide-gap ultrafast laser quartz glass welding with plasma dynamics","authors":"Ning Jiang, Rundong Qian, Huize Yin, Chenyi Ni, Yayun Liu, Haiyu Qiao, Chuanyang Wang","doi":"10.1016/j.jmatprotec.2025.118840","DOIUrl":"10.1016/j.jmatprotec.2025.118840","url":null,"abstract":"<div><div>Ultrafast lasers have the advantages of high speed, small heat-affected zones, and non-contact processing. They can achieve fine welding in the field of microelectronic packaging, improve product quality, and reduce losses. However, ultrafast laser glass welding under wide-gap conditions faces challenges such as insufficient filling and an unstable molten pool, which limit its operability in practical applications. In this study the factors influencing welding strength are investigated by studying the interaction mechanism between the laser and glass, plasma density evolution, and temperature field analysis. First, the principle of irreversible expansion occurring in large gaps during welding was analyzed, and the welding results under different conditions were explained according to this principle. Avalanche ionization and photoionization are key mechanisms of plasma-induced irreversible expansion. Second, to obtain the optimal process parameters for use in the experiment, the plasma density and temperature field were numerically simulated, which reduced the experimental group and improved the experimental efficiency. Finally, the relationships between the process parameters, cavity shape, and welding strength were verified in an experiment involving ultrafast laser welding of quartz glass. The revealed plasma–cavity interaction mechanism and predictive modeling framework are applicable to a broad class of transparent dielectrics, offering a transferable scientific basis for precision laser joining. This work provides foundational insights into laser–matter interaction under wide-gap conditions and supports future extensions to heterogeneous material systems, complex interface geometries, and high-integration photonic manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118840"},"PeriodicalIF":6.7,"publicationDate":"2025-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143768025","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}

引用次数: 0

Laser powder bed fusion: Defect type influences critical porosity re-growth during reheating after hot isostatic pressing

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-04-01 DOI: 10.1016/j.jmatprotec.2025.118839

Jakob Schröder , Tobias Fritsch , Bruno Ferrari , Mika León Altmann , Giovanni Bruno , Anastasiya Toenjes

Despite the remarkable product design flexibility offered by additive manufacturing (AM) techniques, such as laser powder bed fusion, AM processes are susceptible to the formation of defects. In this context, the control of process parameters and the application of post-processing treatments, such as hot isostatic pressing (HIP), are of paramount importance to achieve the desired mechanical properties. The present study investigates the effectiveness of HIP as a function of process parameters in laser powder bed fused Ti-6V-4Al (PBF-LB/Ti64) using X-ray computed tomography. The process parameters are modified to obtain reference samples with low porosity, lack of fusion defects, or keyhole porosity. In all instances, subsurface keyhole porosity was observed in the as-built parts. Moreover, it was found that the efficacy of pore closure is dependent on the specific defect type. In the case of low porosity and keyhole pores, HIP resulted in effective closure. Conversely, larger lack of fusion defects were not closed due to their interconnectivity and the entrapment of argon gas. Subsequent heat treatments above the β-transus temperature allowed the investigation of the impact of defect type on porosity re-growth. For the first time, we reveal that lack of fusion defects are affected by considerable pore re-growth during post-HIP heat treatments of PBF-LB/Ti64. Such phenomenon is driven by the increasing internal pore pressure and local creep deformation at high temperatures. In contrast, re-growth is limited in samples with low porosity or keyhole pores.

{"title":"Laser powder bed fusion: Defect type influences critical porosity re-growth during reheating after hot isostatic pressing","authors":"Jakob Schröder , Tobias Fritsch , Bruno Ferrari , Mika León Altmann , Giovanni Bruno , Anastasiya Toenjes","doi":"10.1016/j.jmatprotec.2025.118839","DOIUrl":"10.1016/j.jmatprotec.2025.118839","url":null,"abstract":"<div><div>Despite the remarkable product design flexibility offered by additive manufacturing (AM) techniques, such as laser powder bed fusion, AM processes are susceptible to the formation of defects. In this context, the control of process parameters and the application of post-processing treatments, such as hot isostatic pressing (HIP), are of paramount importance to achieve the desired mechanical properties. The present study investigates the effectiveness of HIP as a function of process parameters in laser powder bed fused Ti-6V-4Al (PBF-LB/Ti64) using X-ray computed tomography. The process parameters are modified to obtain reference samples with low porosity, lack of fusion defects, or keyhole porosity. In all instances, subsurface keyhole porosity was observed in the as-built parts. Moreover, it was found that the efficacy of pore closure is dependent on the specific defect type. In the case of low porosity and keyhole pores, HIP resulted in effective closure. Conversely, larger lack of fusion defects were not closed due to their interconnectivity and the entrapment of argon gas. Subsequent heat treatments above the β-transus temperature allowed the investigation of the impact of defect type on porosity re-growth. For the first time, we reveal that lack of fusion defects are affected by considerable pore re-growth during post-HIP heat treatments of PBF-LB/Ti64. Such phenomenon is driven by the increasing internal pore pressure and local creep deformation at high temperatures. In contrast, re-growth is limited in samples with low porosity or keyhole pores.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118839"},"PeriodicalIF":6.7,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800439","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}

引用次数: 0

Evolution of surface and subsurface properties of Zr-4 alloy under the combined effects of laser heat treatment and laser gas nitriding: Microscopic morphology, chemical composition, and mechanical behavior

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-29 DOI: 10.1016/j.jmatprotec.2025.118833

Puhong Xu , Yongfeng Qian , Hong An , Haolin Guo , Zhiyu Zhang , Minqiang Jiang , Hu Huang , Jiwang Yan

Zr-4 alloy, extensively employed as cladding in nuclear reactor fuel rods, stands as the foremost line of defense for reactor safety. Given its susceptibility to defects such as micro-pores during casting and its long-term exposure to extreme conditions during practical service processes, enhancing the surface and subsurface properties of Zr-4 alloy is essential. Herein, a nanosecond pulsed laser is used to irradiate the Zr-4 alloy in a nitrogen environment to investigate the evolution of its surface and subsurface properties under the combined effects of laser heat treatment and laser gas nitriding. The experimental results reveal a remarkable augmentation in surface hardness and scratch resistance of the Zr-4 alloy after laser irradiation. Notably, the hardness of the laser-irradiated surface obtained with a laser power of 23.0 W and a scanning speed of 150 mm/s reaches 19.10 GPa, which is more than 7 times higher than that of the untreated surface (2.37 GPa). These improvements are attributed to the synergistic effects of the introduction of hard ZrN phase, the reduction of subsurface porosity, and grain refinement. This study demonstrates a promising approach for significantly improving the mechanical properties of Zr-4 alloy, holding considerable practical significance for its applications in the nuclear energy industry and other relevant fields.

{"title":"Evolution of surface and subsurface properties of Zr-4 alloy under the combined effects of laser heat treatment and laser gas nitriding: Microscopic morphology, chemical composition, and mechanical behavior","authors":"Puhong Xu , Yongfeng Qian , Hong An , Haolin Guo , Zhiyu Zhang , Minqiang Jiang , Hu Huang , Jiwang Yan","doi":"10.1016/j.jmatprotec.2025.118833","DOIUrl":"10.1016/j.jmatprotec.2025.118833","url":null,"abstract":"<div><div>Zr-4 alloy, extensively employed as cladding in nuclear reactor fuel rods, stands as the foremost line of defense for reactor safety. Given its susceptibility to defects such as micro-pores during casting and its long-term exposure to extreme conditions during practical service processes, enhancing the surface and subsurface properties of Zr-4 alloy is essential. Herein, a nanosecond pulsed laser is used to irradiate the Zr-4 alloy in a nitrogen environment to investigate the evolution of its surface and subsurface properties under the combined effects of laser heat treatment and laser gas nitriding. The experimental results reveal a remarkable augmentation in surface hardness and scratch resistance of the Zr-4 alloy after laser irradiation. Notably, the hardness of the laser-irradiated surface obtained with a laser power of 23.0 W and a scanning speed of 150 mm/s reaches 19.10 GPa, which is more than 7 times higher than that of the untreated surface (2.37 GPa). These improvements are attributed to the synergistic effects of the introduction of hard ZrN phase, the reduction of subsurface porosity, and grain refinement. This study demonstrates a promising approach for significantly improving the mechanical properties of Zr-4 alloy, holding considerable practical significance for its applications in the nuclear energy industry and other relevant fields.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118833"},"PeriodicalIF":6.7,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143746689","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}

引用次数: 0

Study on element mixing of titanium-stainless steel dissimilar metal welding pool and its effect on joint properties in nanosecond laser welding

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-29 DOI: 10.1016/j.jmatprotec.2025.118836

Xiang Wang , Rui-Hua Qiao , Yu-Ruo Zhang , Jun Ma , Che-Ping Liang , Lin-Jie Zhang , Suck-Joo Na

During the melting welding of titanium-stainless steel dissimilar metals, intermetallic compounds typically form within the weld seam, significantly compromising its mechanical properties. This study firstly used nanosecond pulse laser achieved effective welding of thin wall titanium and stainless steels by adjusting the mixing ratio of metal elements in the weld seam. A computational fluid dynamics (CFD) calculation model for thin-walled stainless steel titanium nanosecond pulse laser welding was established, and the physical mechanism of element mixing behavior was revealed. The effects of varying heat inputs on fluid flow, mixing of elements, and the evolution of microstructure in the weld pool were investigated. Regardless of whether the melting pool penetrates the titanium thin wall, titanium elements easily accumulate along the edges of the melting pool on the stainless steel side. When the melting pool fully penetrates the titanium sheet, the average titanium content in the weld seam exceeds 23 at%. Conversely, when the bottom of the melting pool is situated at the center of the titanium thin wall, the average titanium content within the weld seam is approximately 9.99 at%. No intermetallic compounds were found in the weld seam the strength of the weld can be increased about twice. Controlling the average content of Ti element in the weld seam to not exceed 10 at% is a key factor in obtaining excellent mechanical properties of welded joints, and it providing new welding strategies for titanium-stainless steel metal welding.

{"title":"Study on element mixing of titanium-stainless steel dissimilar metal welding pool and its effect on joint properties in nanosecond laser welding","authors":"Xiang Wang , Rui-Hua Qiao , Yu-Ruo Zhang , Jun Ma , Che-Ping Liang , Lin-Jie Zhang , Suck-Joo Na","doi":"10.1016/j.jmatprotec.2025.118836","DOIUrl":"10.1016/j.jmatprotec.2025.118836","url":null,"abstract":"<div><div>During the melting welding of titanium-stainless steel dissimilar metals, intermetallic compounds typically form within the weld seam, significantly compromising its mechanical properties. This study firstly used nanosecond pulse laser achieved effective welding of thin wall titanium and stainless steels by adjusting the mixing ratio of metal elements in the weld seam. A computational fluid dynamics (CFD) calculation model for thin-walled stainless steel titanium nanosecond pulse laser welding was established, and the physical mechanism of element mixing behavior was revealed. The effects of varying heat inputs on fluid flow, mixing of elements, and the evolution of microstructure in the weld pool were investigated. Regardless of whether the melting pool penetrates the titanium thin wall, titanium elements easily accumulate along the edges of the melting pool on the stainless steel side. When the melting pool fully penetrates the titanium sheet, the average titanium content in the weld seam exceeds 23 at%. Conversely, when the bottom of the melting pool is situated at the center of the titanium thin wall, the average titanium content within the weld seam is approximately 9.99 at%. No intermetallic compounds were found in the weld seam the strength of the weld can be increased about twice. Controlling the average content of Ti element in the weld seam to not exceed 10 at% is a key factor in obtaining excellent mechanical properties of welded joints, and it providing new welding strategies for titanium-stainless steel metal welding.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"340 ","pages":"Article 118836"},"PeriodicalIF":6.7,"publicationDate":"2025-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143800437","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}

引用次数: 0

Magnetic pulse welding of high-strength aluminum alloy with enhanced Lorentz force via novel hollow field shaper

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-27 DOI: 10.1016/j.jmatprotec.2025.118829

Junjia Cui , Wanting You , Hao Sun , Guangyao Li , Peng Wang , Qing Wang , Chenling Zheng , Chong Wang , Hao Jiang

Magnetic pulse welding (MPW) has been widely applied to join metallic tubes in the automotive and aerospace fields. However, low energy utilization of the device limits the Lorentz force and the application to high-strength alloys. A novel hollow field shaper structure is proposed to expand the range of potentially applicable materials. Topology optimization was employed to trade off the efficiency and the strength of the device. The welding of 6061-T6 aluminum-alloy tube and 1020 steel tube was realized. The joint strength has increased threefold. The results showed that under the enhanced Lorentz force, the element was diffused into each other. The numerical study found that the Lorentz force from the novel design was enhanced by 56 %. The radial deformation in the free deformation experiment increased by 243.3 %, validating the improvement of the force. By creating an analytical model, it was analyzed that the increase in force was due to the decrease in current division on the sloping surface of the hollow field shaper. Besides, the efficiency increased by 66.7 % implying lower energy costs. Thus, the proposed structure was validated to expand the materials range of MPW.

{"title":"Magnetic pulse welding of high-strength aluminum alloy with enhanced Lorentz force via novel hollow field shaper","authors":"Junjia Cui , Wanting You , Hao Sun , Guangyao Li , Peng Wang , Qing Wang , Chenling Zheng , Chong Wang , Hao Jiang","doi":"10.1016/j.jmatprotec.2025.118829","DOIUrl":"10.1016/j.jmatprotec.2025.118829","url":null,"abstract":"<div><div>Magnetic pulse welding (MPW) has been widely applied to join metallic tubes in the automotive and aerospace fields. However, low energy utilization of the device limits the Lorentz force and the application to high-strength alloys. A novel hollow field shaper structure is proposed to expand the range of potentially applicable materials. Topology optimization was employed to trade off the efficiency and the strength of the device. The welding of 6061-T6 aluminum-alloy tube and 1020 steel tube was realized. The joint strength has increased threefold. The results showed that under the enhanced Lorentz force, the element was diffused into each other. The numerical study found that the Lorentz force from the novel design was enhanced by 56 %. The radial deformation in the free deformation experiment increased by 243.3 %, validating the improvement of the force. By creating an analytical model, it was analyzed that the increase in force was due to the decrease in current division on the sloping surface of the hollow field shaper. Besides, the efficiency increased by 66.7 % implying lower energy costs. Thus, the proposed structure was validated to expand the materials range of MPW.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118829"},"PeriodicalIF":6.7,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143739861","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}

引用次数: 0

Property enhancement in 6D10 aluminum alloy welds: A comparative study of CMT+P and oscillating laser welding techniques with novel Al-Si-Cu-Mg-Zn filler wire

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-27 DOI: 10.1016/j.jmatprotec.2025.118830

Xianwei Jiang , Shuncun Luo , Meng Cao , Xiaonan Wang , Hiromi Nagaumi , Zengrong Hu

To solve the issue of weld softening encountered when welding high-strength aluminum alloy with conventional commercial welding wires, this study uses two welding techniques, Cold Metal Transfer Plus Pulse (CMT+P) and Oscillating Laser Welding with Filler Wire (OLWFW), to weld 6D10 aluminum alloy with a novel Al-Si-Cu-Mg-Zn wire. The porosity, microstructure, and mechanical properties of the welded joints are compared. Results show that minimum porosity is 0.42 % in the CMT+P process and 0.11 % in the OLWFW process. Metallurgical pores mainly affect yield strength and ultimate tensile strength, with less impact on elongation. CMT+P produces β'' and θ' strengthening phases (lower number density, larger size) in the weld seam when using Al-Si-Cu-Mg-Zn filler wire, while OLWFW (higher cooling rate) produces finer cellular sub-structures and higher density of smaller β''+ θ'+Q′ strengthening phases. Mechanical properties show that CMT+P joints have 284.5 MPa ultimate tensile strength in the weld seam and 252.5 MPa in the heat-affected zone, which increase to 311.5 MPa and 301.5 MPa respectively with OLWFW. Strengthening mechanisms quantified via dislocation shearing and Orowan mechanisms indicate that OLWFW exhibits greater precipitation strengthening than CMT+P, explaining the strength difference. This study discovered that filling with Al-Si-Cu-Mg-Zn welding wire can precipitate a significant amount of strengthening phase in the weld seam without post-weld heat treatment, especially when using the OLWFW welding technique with a higher cooling rate. This provides a new strategy for welding high-strength aluminum alloys: using novel multi-alloyed filler wires and high-cooling-rate welding techniques can improve both the strength of the weld seam and the welding coefficient, facilitating the broader application of high-strength aluminum alloys in vehicle manufacturing.

{"title":"Property enhancement in 6D10 aluminum alloy welds: A comparative study of CMT+P and oscillating laser welding techniques with novel Al-Si-Cu-Mg-Zn filler wire","authors":"Xianwei Jiang , Shuncun Luo , Meng Cao , Xiaonan Wang , Hiromi Nagaumi , Zengrong Hu","doi":"10.1016/j.jmatprotec.2025.118830","DOIUrl":"10.1016/j.jmatprotec.2025.118830","url":null,"abstract":"<div><div>To solve the issue of weld softening encountered when welding high-strength aluminum alloy with conventional commercial welding wires, this study uses two welding techniques, Cold Metal Transfer Plus Pulse (CMT+P) and Oscillating Laser Welding with Filler Wire (OLWFW), to weld 6D10 aluminum alloy with a novel Al-Si-Cu-Mg-Zn wire. The porosity, microstructure, and mechanical properties of the welded joints are compared. Results show that minimum porosity is 0.42 % in the CMT+P process and 0.11 % in the OLWFW process. Metallurgical pores mainly affect yield strength and ultimate tensile strength, with less impact on elongation. CMT+P produces β'' and θ' strengthening phases (lower number density, larger size) in the weld seam when using Al-Si-Cu-Mg-Zn filler wire, while OLWFW (higher cooling rate) produces finer cellular sub-structures and higher density of smaller β''+ θ'+Q′ strengthening phases. Mechanical properties show that CMT+P joints have 284.5 MPa ultimate tensile strength in the weld seam and 252.5 MPa in the heat-affected zone, which increase to 311.5 MPa and 301.5 MPa respectively with OLWFW. Strengthening mechanisms quantified via dislocation shearing and Orowan mechanisms indicate that OLWFW exhibits greater precipitation strengthening than CMT+P, explaining the strength difference. This study discovered that filling with Al-Si-Cu-Mg-Zn welding wire can precipitate a significant amount of strengthening phase in the weld seam without post-weld heat treatment, especially when using the OLWFW welding technique with a higher cooling rate. This provides a new strategy for welding high-strength aluminum alloys: using novel multi-alloyed filler wires and high-cooling-rate welding techniques can improve both the strength of the weld seam and the welding coefficient, facilitating the broader application of high-strength aluminum alloys in vehicle manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118830"},"PeriodicalIF":6.7,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143760286","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}

引用次数: 0

Unveiling the mechanism behind high formability in ultrafine-grained Cu with low ductility

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-27 DOI: 10.1016/j.jmatprotec.2025.118828

Huimin Liu , Yao Jiang , Wen Yang , Zhonghua Liu , Junyu Ke , Saiyang Li , Fan Liu , Xinping Zhang , Jing Tao Wang

To explore the formability of ultrafine-grained (UFG) materials, hemispherical spinning tests are conducted on the UFG Cu for the first time. The limit half-cone angle of spinning for UFG Cu is experimentally determined to be 15.2°, slightly higher than the 7.84° for coarse-grained (CG) Cu, despite UFG Cu exhibiting significantly lower tensile ductility than the latter. The exceptional formability of UFG Cu is primarily attributed to the mechanism of deformation-induced dynamic recovery during spinning, which promotes dislocation absorption via grain boundary migration and releases the strain/strain concentration at grain boundaries. Finite element method (FEM) simulations confirm that fracture in both UFG and CG materials predominantly occurs in the cone wall region due to its biaxial tensile stress state. In contrast, the spinning deformation zone exhibits a triaxial compressive stress state, which serves as an optimal constraint for accommodating large plastic strains within large ranges of strain rates. By adjusting key processing parameters, such as feed ratio and rotational speed, the extent of dynamic recovery can be effectively activated and enhanced. These findings provide new insights into the plastic forming behavior of UFG Cu and expand its potential for engineering applications.

{"title":"Unveiling the mechanism behind high formability in ultrafine-grained Cu with low ductility","authors":"Huimin Liu , Yao Jiang , Wen Yang , Zhonghua Liu , Junyu Ke , Saiyang Li , Fan Liu , Xinping Zhang , Jing Tao Wang","doi":"10.1016/j.jmatprotec.2025.118828","DOIUrl":"10.1016/j.jmatprotec.2025.118828","url":null,"abstract":"<div><div>To explore the formability of ultrafine-grained (UFG) materials, hemispherical spinning tests are conducted on the UFG Cu for the first time. The limit half-cone angle of spinning for UFG Cu is experimentally determined to be 15.2°, slightly higher than the 7.84° for coarse-grained (CG) Cu, despite UFG Cu exhibiting significantly lower tensile ductility than the latter. The exceptional formability of UFG Cu is primarily attributed to the mechanism of deformation-induced dynamic recovery during spinning, which promotes dislocation absorption via grain boundary migration and releases the strain/strain concentration at grain boundaries. Finite element method (FEM) simulations confirm that fracture in both UFG and CG materials predominantly occurs in the cone wall region due to its biaxial tensile stress state. In contrast, the spinning deformation zone exhibits a triaxial compressive stress state, which serves as an optimal constraint for accommodating large plastic strains within large ranges of strain rates. By adjusting key processing parameters, such as feed ratio and rotational speed, the extent of dynamic recovery can be effectively activated and enhanced. These findings provide new insights into the plastic forming behavior of UFG Cu and expand its potential for engineering applications.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118828"},"PeriodicalIF":6.7,"publicationDate":"2025-03-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143746690","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}

引用次数: 0

Tailoring microstructure and strengthening mechanism of anisotropic elastocaloric effect in NiTi shape memory alloys by laser directed energy deposition scanning strategy

IF 6.7 2区材料科学 Q1 ENGINEERING, INDUSTRIAL

Journal of Materials Processing Technology

Pub Date : 2025-03-26 DOI: 10.1016/j.jmatprotec.2025.118825

Shuyao Wang, Yongjun Shi, Xuejin Zhao, Kaijun Fan, Ying Li, Qin Wang

The NiTi shape memory alloys (SMAs) with elastocaloric effect are applied to new solid-state refrigeration technologies with green and zero-global warming potential, and additive manufacturing technologies provide new opportunities to advance their development. In this study, four scanning strategies for laser directed energy deposition (LDED) additive manufacturing involving the direction change of adjacent hatch lines and the rotation of adjacent deposited layers were designed, and the NiTi SMAs were synthesized in situ from two metal powders, Ni and Ti. The microstructure evolutionary behaviors and reinforcement mechanisms of anisotropic elastocaloric effects were analyzed. The rotation of two adjacent deposited layers demonstrates the potential to inhibit the growth of Ti₂Ni precipitation phase dendrite arms and to modulate their morphology and content, and to disperse the direction of the temperature gradient and reduce the stresses and deformations resulting from the thermal cycling process. The differences in microstructure evolution behaviors of different scanning strategies make NiTi SMAs exhibit anisotropy in stress-strain response behaviors and elastocaloric effects. The results of the analysis of the elastocaloric effect show that the temperature drop generated at the surface of the alloy is a linearly increasing function of the maximum compressive stress. The customized microstructure of “semicircular arc” shaped grains within the double cross-section was obtained by the simultaneous rotation of adjacent hatch lines and deposited layers, exhibiting a synergistic enhancement of phase strain and elastocaloric effects. The cooling effect up to −9.4 °C (unloaded at 1100 MPa) was increased by 224 % compared to the conventional strategy. This study provides a way to advance the rapid development of solid-state refrigeration technology by customizing the microstructure of NiTi SMAs and obtaining the desired elastocaloric effect via LDED additive manufacturing.

{"title":"Tailoring microstructure and strengthening mechanism of anisotropic elastocaloric effect in NiTi shape memory alloys by laser directed energy deposition scanning strategy","authors":"Shuyao Wang, Yongjun Shi, Xuejin Zhao, Kaijun Fan, Ying Li, Qin Wang","doi":"10.1016/j.jmatprotec.2025.118825","DOIUrl":"10.1016/j.jmatprotec.2025.118825","url":null,"abstract":"<div><div>The NiTi shape memory alloys (SMAs) with elastocaloric effect are applied to new solid-state refrigeration technologies with green and zero-global warming potential, and additive manufacturing technologies provide new opportunities to advance their development. In this study, four scanning strategies for laser directed energy deposition (LDED) additive manufacturing involving the direction change of adjacent hatch lines and the rotation of adjacent deposited layers were designed, and the NiTi SMAs were synthesized in situ from two metal powders, Ni and Ti. The microstructure evolutionary behaviors and reinforcement mechanisms of anisotropic elastocaloric effects were analyzed. The rotation of two adjacent deposited layers demonstrates the potential to inhibit the growth of Ti<sub>2</sub>Ni precipitation phase dendrite arms and to modulate their morphology and content, and to disperse the direction of the temperature gradient and reduce the stresses and deformations resulting from the thermal cycling process. The differences in microstructure evolution behaviors of different scanning strategies make NiTi SMAs exhibit anisotropy in stress-strain response behaviors and elastocaloric effects. The results of the analysis of the elastocaloric effect show that the temperature drop generated at the surface of the alloy is a linearly increasing function of the maximum compressive stress. The customized microstructure of “semicircular arc” shaped grains within the double cross-section was obtained by the simultaneous rotation of adjacent hatch lines and deposited layers, exhibiting a synergistic enhancement of phase strain and elastocaloric effects. The cooling effect up to −9.4 °C (unloaded at 1100 MPa) was increased by 224 % compared to the conventional strategy. This study provides a way to advance the rapid development of solid-state refrigeration technology by customizing the microstructure of NiTi SMAs and obtaining the desired elastocaloric effect via LDED additive manufacturing.</div></div>","PeriodicalId":367,"journal":{"name":"Journal of Materials Processing Technology","volume":"339 ","pages":"Article 118825"},"PeriodicalIF":6.7,"publicationDate":"2025-03-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143725319","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}

引用次数: 0